U.S. patent application number 16/068905 was filed with the patent office on 2019-01-10 for panel-like formed product, vehicle door, and method for manufacturing a panel-like formed product.
The applicant listed for this patent is NIPPON STEEL & SUMITOMO METAL CORPORATION. Invention is credited to Yoshiyuki KASEDA, Takeshi KAWACHI, Yoshiaki NAKAZAWA, Kenichiro OTSUKA.
Application Number | 20190009654 16/068905 |
Document ID | / |
Family ID | 59398711 |
Filed Date | 2019-01-10 |
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United States Patent
Application |
20190009654 |
Kind Code |
A1 |
OTSUKA; Kenichiro ; et
al. |
January 10, 2019 |
PANEL-LIKE FORMED PRODUCT, VEHICLE DOOR, AND METHOD FOR
MANUFACTURING A PANEL-LIKE FORMED PRODUCT
Abstract
An object of the present invention is to provide a panel-like
formed product having an excellent collision property. The
panel-like formed product (1) includes a polygonal top board (2),
two or more vertical walls (5), and a flange (7). The vertical
walls (5) extend from two or more sides of the top board (2), and
include at least two adjacent vertical walls (5) extending from at
least two adjacent sides of the top board (2). The flange (7)
connects to lower ends of the vertical walls (5) and spreads in
directions in which the top board (2) spreads. The top board (2)
includes a frame portion (3) including the two or more sides of the
top board from which the vertical walls extend, and a concave
portion (4) which is located at an inner side of the frame portion
(3) and recedes from the frame portion (3). The two or more
adjacent vertical walls (5) include a first vertical wall section
(5A), a stair (6), and a second vertical wall section (5B). The
stair (6) connects to a lower end of the first vertical wall
section (5A) and spreads in the directions in which the top board
spreads. The second vertical wall section (5B) connects to an outer
edge of the stair (6) and extends in a direction in which the first
vertical wall section (5A) extends. The flange (7) connects to a
lower end of the second vertical wall section (5B).
Inventors: |
OTSUKA; Kenichiro;
(Chiyoda-ku, Tokyo, JP) ; NAKAZAWA; Yoshiaki;
(Chiyoda-ku, Tokyo, JP) ; KAWACHI; Takeshi;
(Chiyoda-ku, Tokyo, JP) ; KASEDA; Yoshiyuki;
(Chiyoda-ku, Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIPPON STEEL & SUMITOMO METAL CORPORATION |
Tokyo |
|
JP |
|
|
Family ID: |
59398711 |
Appl. No.: |
16/068905 |
Filed: |
January 27, 2017 |
PCT Filed: |
January 27, 2017 |
PCT NO: |
PCT/JP2017/003040 |
371 Date: |
July 10, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 53/88 20130101;
B60J 5/0415 20130101; B21D 22/02 20130101; B21D 22/20 20130101;
B21D 22/208 20130101; B60J 5/0413 20130101; B21D 47/00
20130101 |
International
Class: |
B60J 5/04 20060101
B60J005/04; B21D 53/88 20060101 B21D053/88; B21D 47/00 20060101
B21D047/00; B21D 22/02 20060101 B21D022/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 28, 2016 |
JP |
2016-014849 |
Mar 25, 2016 |
JP |
2016-061873 |
Claims
1. A panel-like formed product made of a metal plate, the
panel-like formed product comprising: a polygonal top board, two or
more vertical walls extending from two or more sides of the top
board among all sides of the top board defining an outer edge of
the top board, the vertical walls including at least two adjacent
vertical walls extending from at least two adjacent sides of the
top board; and a flange connecting to lower ends of the vertical
walls and spreading in directions in which the top board spreads;
wherein: the top board includes: a frame portion including the two
or more sides of the top board from which the vertical walls
extend; and a concave portion which is located at an inner side of
the frame portion and recedes from the frame portion; the at least
two adjacent vertical walls include: a first vertical wall section;
a stair connecting to a lower end of the first vertical wall
section and spreading in the directions in which the top board
spreads; and a second vertical wall section connecting to an outer
edge of the stair and extending in a direction in which the first
vertical wall section extends; and the flange connects to a lower
end of the second vertical wall section.
2. The panel-like formed product according to claim 1, wherein the
frame portion has a width W (mm) which satisfies a condition
expressed by formula (1), in which L denotes a maximum width (mm)
of the top board. 10<W<0.2.times.L (1)
3. The panel-like formed product according to claim 1, wherein a
distance between the frame portion and a bottom face of the concave
portion is greater than a distance between the frame portion and
the stair.
4. The panel-like formed product according to claim 1 any, wherein
the metal plate is a steel plate having a tensile strength of not
less than 340 MPa.
5. The panel-like formed product according to claim 4, wherein the
metal plate is a steel plate having a tensile strength of not less
than 600 MPa.
6. The panel-like formed product according to claim 1, wherein the
concave portion of the top board further includes either a linear
depression depressed into a bottom face of the concave portion or a
projection projecting from the bottom face of the concave portion,
or both.
7. The panel-like formed product according to claim 1, wherein the
metal plate is a tailored blank.
8. The panel-like formed product according to claim 1, wherein: the
panel-like formed product is to be used as a door inner panel of a
vehicle; and none of the vertical walls and the frame portion
extends from a side to be positioned at an upper side in the
vehicle, among all sides of the top board defining the outer edge
of the top board.
9. A vehicle door to be used in a vehicle, comprising: the
panel-like formed product according to claim 7; a door outer panel
located in an outer portion of the vehicle, at an outer side of the
panel-like formed product, and joined with the panel-like formed
product; and a window member capable of being housed in the concave
portion, the window member being located in an inner portion of the
vehicle, at an inner side of the panel-like formed product.
10. A method for manufacturing the panel-like formed product
according to claim 1, the method comprising: a preparing step of
preparing a blank made of a steel plate; an intermediate pressing
step of pressing the blank to form the top board and the first
vertical wall section to a height of the stair and thereby
producing an intermediate formed product; a final pressing step of
pressing the intermediate formed product by using a final pressing
machine and thereby producing the panel-like formed product;
wherein: the final pressing machine includes: a center die
including an end surface having a shape corresponding to a shape of
a portion of the panel-like formed product from the top board to
the outer edge of the stair; a blank holder located at an outer
side of the center die and adjacent to the center die; a center
punch facing the center die, the center punch including an end
surface having a shape corresponding to the shape of the portion of
the panel-like formed product from the top board to the outer edge
of the stair; and an outer punch located at an outer side of the
center punch and adjacent to the center punch, the outer punch
facing the blank holder; and the final pressing step includes: an
early step of placing the intermediate formed product on the center
die, and pinching the intermediate formed product between the
center punch and the center die and further between the outer punch
and the blank holder; and a late step of moving the outer punch and
the blank holder with the intermediate formed product pinched in
between relative to the center punch and the center die with the
intermediate formed product pinched in between to form the second
vertical wall section and the flange and thereby producing the
panel-like formed product.
11. The method for manufacturing a panel-like formed product
according to claim 10, wherein: the final pressing step further
includes a heating step of heating the intermediate formed product;
in the final pressing step, the heated intermediate formed product
is pressed and quenched, and thereby the intermediate formed
product is formed into the panel-like formed product; and the early
step of the final pressing step includes: a first step of placing
the heated intermediate formed product on the center die, pinching
the intermediate formed product between the center punch and the
center die, and bringing the outer punch into contact with the
intermediate formed product; and a second step of, after bringing
the outer punch into contact with the intermediate formed product,
while keeping the intermediate formed product pinched between the
center punch and the center die, bringing the blank holder into
contact with the intermediate formed product to pinch the
intermediate formed product between the outer punch and the blank
holder.
12. The method for manufacturing a panel-like formed product
according to claim 11, wherein in the first step, the blank holder
is positioned such that the end surface of the blank holder is at a
height lower than a height of a stair portion of the end surface of
the center die corresponding to the stair of the panel-like formed
product.
13. The method for manufacturing a panel-like formed product
according to claim 12, wherein the steel plate is a tailored blank.
Description
TECHNICAL FIELD
[0001] The present invention relates to a panel-like formed
product, a vehicle door, and a method for manufacturing a
panel-like formed product. More specifically, the present invention
relates to a panel-like formed product suited for use as a door
inner panel for an automobile or any other vehicle, a vehicle door
usable in an automobile or any other vehicle, and a method for
manufacturing a panel-like formed product.
BACKGROUND ART
[0002] An automobile door is produced typically by fitting a door
inner panel and a door outer panel together. A window, a window
drive device, an audio speaker, a handle, and other various
components are to be attached to the automobile door. For set-in of
these components, a space must be made between the door inner panel
and the door outer panel. In order to make the space, for example,
vertical walls are made in the door inner panel. Also, when the
door is closed, the inside of the automobile must be sealed by the
door. In order to seal the inside of the automobile, for example, a
stair is provided in the vertical walls of the door inner panel.
The stair of the vertical walls is caused to face a pillar or the
like of the vehicle body, and this ensures tight sealing of the
inside of the automobile.
[0003] The door inner panel is produced by press working of a steel
plate. Such a door inner panel generally has a complicated shape,
and accordingly, in producing such a door inner panel, it is
necessary to deform a steel plate largely. In this case, the door
inner panel after the press working may have cracks, wrinkles, and
the like. In order to suppress generation of cracks, wrinkles, and
the like, usually, a soft steel plate with high workability is used
as the material of the door inner panel.
[0004] However, the soft steel plate has low strength. Accordingly,
a door inner panel formed of a soft steel plate has low strength.
Therefore, a reinforcing member (for example, a beltline
reinforcement, a door impact beam, and the like) is often attached
to the door inner panel.
[0005] Door inner panels are disclosed, for example, in Japanese
Patent Application Publication No. 2007-296953 (Patent Literature
1), Japanese Patent Application Publication No. 2008-94353 (Patent
Literature 2) and Japanese Patent Application Publication No.
2013-112133 (Patent Literature 3).
[0006] The door inner panel disclosed in Patent Literature 1
includes a beltline reinforcement. The beltline reinforcement is
attached to a beltline portion of the door inner panel and extends
in the front-rear direction of the vehicle. Patent Literature 1
states that the beltline reinforcement bears a collision load
applied to the vehicle in the vehicle front-rear direction, which
effectively decreases the bending moment acting on the beltline
portion.
[0007] In the door inner panel disclosed in Patent Literature 2,
when a collision load is applied from a side of a vehicle, the door
inner panel and the beltline reinforcement contact with each other,
and a load absorbing portion of the door inner panel is deformed.
Patent Literature 2 states that the load absorbing portion absorbs
a part of a load applied in the thickness direction of the door
inner panel, which ensures rigidity of the door inner panel.
[0008] In the side door disclosed in Patent literature 3, the rear
end portion and the front end portion of a beltline reinforcement
formed by hot stamping have strength and rigidity which are lower
than those of the body of the beltline reinforcement. Accordingly,
when a collision load is applied from the front side of the
vehicle, the rear end portion of the beltline reinforcement is
plastically deformed, and the contact area between the rear end
portion of the beltline reinforcement and the center pillar
increases. Patent Literature 3 states that the deformation of the
rear end portion of the beltline reinforcement allows absorption of
collision energy.
CITATION LIST
Patent Literatures
[0009] Patent Literature 1: Japanese Patent Application Publication
No. 2007-296953
[0010] Patent Literature 2: Japanese Patent Application Publication
No. 2008-94353
[0011] Patent Literature 3: Japanese Patent Application Publication
No. 2013-112133
SUMMARY OF INVENTION
Technical Problems
[0012] Any of the door inner panels disclosed in Patent Literatures
1, 2 and 3 needs a separate reinforcing member, such as a beltline
reinforcement or the like, to obtain a good collision property.
Therefore, doors produced by using the door inner panels disclosed
in Patent Literatures 1, 2 and 3 are low in production efficiency
and high in cost.
[0013] An object of the present invention is to provide a
panel-like formed product which has an excellent collision
property, a vehicle door including the panel-like formed product,
and a method for manufacturing the panel-like formed product.
Solutions to Problems
[0014] A panel-like formed product according to an embodiment of
the present invention is made of a metal plate. The panel-like
formed product includes a polygonal top board, two or more vertical
walls, and a flange. The vertical walls extend from two or more
sides of the top board among all sides of the top board defining an
outer edge of the top board, and include at least two adjacent
vertical walls extending from at least two adjacent sides of the
top board. The flange connects to lower ends of the vertical walls
and spreads in directions in which the top board spreads. The top
board includes a frame portion and a concave portion. The frame
portion includes the two or more sides of the top board from which
the vertical walls extend. The concave portion is located at an
inner side of the frame portion and recedes from the frame portion.
The at least two adjacent vertical walls include a first vertical
wall section, a stair, and a second vertical wall section. The
stair connects to a lower end of the first vertical wall section
and spreads in the directions in which the top board spreads. The
second vertical wall section connects to an outer edge of the stair
and extends in a direction in which the first vertical wall section
extends. The flange connects to a lower end of the second vertical
wall section.
[0015] A vehicle door includes the panel-like formed product, and a
door outer panel, and a window member. The door outer panel is
located in an outer portion of the vehicle, at an outer side of the
panel-like formed product, and joined with the panel-like formed
product. In this regard, the door outer panel is fastened to the
flange of the panel-like formed product, and the concave portion of
the panel-like formed product projects toward the door outer panel.
The window member is capable of being housed in the concave
portion, and the window member is located in an inner portion of
the vehicle relative to the panel-like formed product.
[0016] A panel-like formed product manufacturing method according
to an embodiment is a method for manufacturing a panel-like formed
product made of a steel plate. The panel-like formed product to be
manufactured has the above-described structure. The manufacturing
method includes a preparing step of preparing a blank made of a
steel plate; an intermediate pressing step of pressing the blank to
form the top board and the first vertical wall section to a height
of the stair and thereby producing an intermediate formed product;
and a final pressing step of pressing the intermediate formed
product by using a final pressing machine and thereby producing the
panel-like formed product. The final pressing machine includes a
center die including an end surface having a shape corresponding to
a shape of a portion of the panel-like formed product from the top
board to the outer edge of the stair; a blank holder located at an
outer side of the center die and adjacent to the center die; a
center punch facing the center die, the center punch including an
end surface having a shape corresponding to a shape of a portion of
the panel-like formed product from the top board to the stair; and
an outer punch located at an outer side of the center punch and
adjacent to the center punch to face the blank holder. The final
pressing step includes: an early step of placing the intermediate
formed product on the center die, and pinching the intermediate
formed product between the center punch and the center die and
further between the outer punch and the blank holder; and a late
step of moving the outer punch and the blank holder with the
intermediate formed product pinched in between relative to the
center punch and the center die with the intermediate formed
product pinched in between to form the second vertical wall section
and the flange and thereby producing the panel-like formed
product.
Advantage Effects of Invention
[0017] The panel-like formed product according to the present
invention has an excellent collision property. The panel-like
formed product manufacturing method according to the present
invention allows production of a panel-like formed product which
has an excellent collision property.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a perspective view of a panel-like formed product
according to an embodiment of the present invention.
[0019] FIG. 2 is a sectional view of a vehicle door in a plane
perpendicular to an up-down direction of a vehicle.
[0020] FIG. 3 is a sectional view of a vehicle door including the
panel-like formed product shown in FIG. 1 as a door inner panel in
a plane perpendicular to an up-down direction of the vehicle.
[0021] FIG. 4 is a perspective view of a panel-like formed product
which is different from the panel-like formed product shown in FIG.
1.
[0022] FIG. 5 is a sectional view of an intermediate formed product
which is an intermediate product of the panel-like formed
product.
[0023] FIG. 6A is a schematic view showing a step of an
intermediate pressing step.
[0024] FIG. 6B is a schematic view showing a step subsequent to the
step shown in FIG. 6A.
[0025] FIG. 6C is a schematic view showing a step subsequent to the
step shown in FIG. 6B.
[0026] FIG. 7A is a schematic view showing a step of a first
intermediate pressing step which is different from the intermediate
pressing step shown in FIGS. 6A to 6C.
[0027] FIG. 7B is a schematic view showing a step subsequent to the
step shown in FIG. 7A.
[0028] FIG. 7C is a schematic view showing a step subsequent to the
step shown in FIG. 7B.
[0029] FIG. 8A is a schematic view showing a step of a second
intermediate pressing step which is carried out after the
intermediate pressing step shown in FIGS. 7A to 7C.
[0030] FIG. 8B is a schematic view showing a step subsequent to the
step shown in FIG. 8A.
[0031] FIG. 8C is a schematic view showing a step subsequent to the
step shown in FIG. 8B.
[0032] FIG. 9 is a schematic view of a heating step carried out
after the intermediate pressing step.
[0033] FIG. 10A is a schematic view of a final pressing machine
used in a final pressing step.
[0034] FIG. 10B is a schematic view showing a step of the final
pressing step carried out after the heating step shown in FIG.
9.
[0035] FIG. 10C is a schematic view showing a step subsequent to
the step shown in FIG. 10B.
[0036] FIG. 10D is a schematic view showing a step subsequent to
the step shown in FIG. 10C.
[0037] FIG. 10E is a schematic view showing a step subsequent to
the step shown in FIG. 10D.
[0038] FIG. 11 is a schematic view showing how wrinkles and the
like are generated during press working.
DETAILED DESCRIPTION OF EMBODIMENTS
[0039] A panel-like formed product according to an embodiment of
the present invention is formed of a metal plate. The panel-like
formed product includes a polygonal top board, two or more vertical
walls, and a flange. The vertical walls extend from two or more
sides of the top board among all sides of the top board defining an
outer edge of the top board, and include at least two adjacent
vertical walls extending from at least two adjacent sides of the
top board. The flange connects to lower ends of the vertical walls
and spreads in directions in which the top board spreads. The top
board includes a frame portion and a concave portion. The frame
portion includes the two or more sides of the top board from which
the vertical walls extend. The concave portion is located at an
inner side of the frame portion and recedes from the frame portion.
The at least two adjacent vertical walls include a first vertical
wall section, a stair, and a second vertical wall section. The
stair connects to a lower end of the first vertical wall section
and spreads in the directions in which the top board spreads. The
second vertical wall section connects to an outer edge of the stair
and extends in a direction in which the first vertical wall section
extends. The flange connects to a lower end of the second vertical
wall section.
[0040] Thus, the panel-like formed product according to the
embodiment includes a concave portion in the top board. The concave
portion improves the collision property of the panel-like formed
product. For example, when the panel-like formed product is
combined with an outer panel or the like, the product made by the
combination has an excellent collision property. Specifically, when
the outer panel or the like is deformed by a collision load, the
deformed outer panel or the like hits against the concave portion
of the panel-like formed product. Then, the concave portion absorbs
the collision energy. The panel-like formed product according to
the present invention has an excellent collision property, and
accordingly, the product in which the panel-like formed product is
used has an excellent collision property.
[0041] The panel-like formed product may be formed by cold
pressing, warm pressing or hot pressing. The panel-like formed
product may be produced by applying hot stamping to an intermediate
formed product having a portion already formed into the portion of
the panel-like formed product from the top board to the stair.
[0042] In the panel-like formed product, the frame portion may have
a width W (mm) which satisfies a condition expressed by formula
(1), in which L denotes a maximum width (mm) of the top board.
10<W<0.2.times.L (1)
[0043] When the width W of the frame portion of the panel-like
formed product satisfies the condition expressed by formula (1),
the concave portion is sufficiently large. Accordingly, the concave
portion can absorb large collision energy. Therefore, the collision
property of the panel-like formed product is further improved.
[0044] In the panel-like formed product, the distance between the
frame portion and a bottom face of the concave portion may be
greater than the distance between the frame portion and the
stair.
[0045] In this case, when the panel-like formed product is combined
with an outer panel and the like to produce a vehicle door, the
distance between the concave portion of the panel-like formed
product and the outer panel is short. In other words, the
panel-like formed product is positioned near the outer panel.
Accordingly, the concave portion of the panel-like formed product
hits against the outer panel and the like at an early stage of
collision. Thereby, the collision property of the vehicle door is
further improved.
[0046] The metal plate which is the material of the panel-like
formed product may be a steel plate. In this case, the steel plate
has a tensile strength of desirably not less than 340 MPa, more
desirably not less than 600 MPa and still more desirably not less
than 1200 MPa.
[0047] In this case, the plate thickness of the panel-like formed
product can be made thinner, and the concave portion can substitute
for a beltline reinforcement, a door impact beam or any other
reinforcing member. This leads to a further weight reduction of the
panel-like formed product.
[0048] The concave portion of the top board further may include
either a linear depression depressed into the bottom face of the
concave portion or a linear projection projecting from the bottom
face of the concave portion, or both. Specifically, the concave
portion of the top board may include a depression and no
projection. The concave portion of the top board may include a
projection and no depression. The concave portion of the top board
may include both a depression and a projection. Here, "linear"
means being like a straight line, like a curved line or like a wavy
line. When the concave portion of the top board includes a
plurality of linear depressions and/or projections, the plurality
of linear depressions and/or projections may cross each other.
[0049] The metal plate which is the material of the panel-like
formed product may be a tailored blank. In this case, it is
possible to heighten the strength of only a specified portion,
which allows a reduction in plate thickness.
[0050] The panel-like formed product may be used as a door inner
panel of an automobile or any other vehicle. In this case, none of
the vertical walls and the frame portion extends from a side to be
positioned at an upper side in the vehicle, among all sides of the
top board defining the outer edge of the top board.
[0051] When the panel-like formed product is used as a door inner
panel of an automobile or any other vehicle, the vehicle door
includes a door outer panel and a window member as well as the
panel-like formed product. The door outer panel is located in an
outer portion of the vehicle, at an outer side of the panel-like
formed product, and joined with the panel-like formed product. In
this regard, the door outer panel is fastened to the flange of the
panel-like formed product in such a way that the concave portion of
the panel-like formed product projects toward the door outer panel.
The window member is capable of being housed in the concave portion
of the panel-like formed product, and is located in an inner
portion of the vehicle, at an inner side of the panel-like formed
product.
[0052] In this case, when a collision load is applied to the outer
panel of the vehicle door, the concave portion of the panel-like
formed product hits against the door outer panel at an early stage.
Accordingly, the collision property of the vehicle door is
improved.
[0053] The window member is a transparent member, and for example,
a window glass. The window member may be made of transparent
resin.
[0054] A panel-like formed product manufacturing method according
to an embodiment of the present invention is a method for
manufacturing a panel-like formed product by using a steel plate as
a material. The panel-like formed product has the above-described
structure. The manufacturing method includes a preparing step, an
intermediate pressing step, and a final pressing step. In the
preparing step, a blank made of a steel plate is prepared. In the
intermediate pressing step, the blank is pressed to form the top
board and the first vertical wall section to a height of the stair,
and thereby an intermediate formed product is produced. In the
final pressing step, the intermediate formed product is pressed by
using a final pressing machine to produce the panel-like formed
product. The final pressing machine includes a center die, a blank
holder, a center punch, and an outer punch. The center die includes
an end surface having a shape corresponding to a shape of a portion
of the panel-like formed product from the top board to the outer
edge of the stair. The blank holder is located at an outer side of
the center die and adjacent to the center die. The center punch
faces the center die, and the center punch includes an end surface
having a shape corresponding to the shape of the portion of the
panel-like formed product from the top board to the outer edge of
the stair. The outer punch is located at an outer side of the
center punch and adjacent to the center punch, and faces the blank
holder. The final pressing step includes an early step and a late
step. In the early step, the intermediate formed product is placed
on the center die, and the intermediate formed product is pinched
between the center punch and the center die and further between the
outer punch and the blank holder. In the late step, the outer punch
and the blank holder with the intermediate formed product pinched
in between is moved relative to the center punch and the center die
with the intermediate formed product pinched in between to form the
second vertical wall section and the flange, and thereby the
panel-like formed product is produced.
[0055] In the panel-like formed product manufacturing method
according to the embodiment, the panel-like formed product is
manufactured in two-stage pressing including an intermediate
pressing step and a final pressing step. Thereby, even a panel-like
formed product having a difficult-to-form shape can be manufactured
while generation of wrinkles and cracks is suppressed during the
pressing. Here, a difficult-to-form shape means such a shape of the
panel-like formed product as described above in which a stair is
made in adjacent vertical walls.
[0056] The manufacturing method may further include a heating step
of heating the intermediate formed product to be executed before
the final pressing step. In this case, in the final pressing step,
the heated intermediate formed product is pressed and quenched, and
thereby, the panel-like formed product is produced. In this case,
the early step of the final pressing step includes a first step and
a second step. In the first step, the heated intermediate formed
product is placed on the center die and pinched between the center
punch and the center die, and the outer punch is brought into
contact with the intermediate formed product. In the second step,
after the outer punch is brought into contact with the intermediate
formed product, while the intermediate formed product is kept
pinched between the center punch and the center die, the blank
holder is brought into contact with the intermediate formed product
to pinch the intermediate formed product between the outer punch
and the blank holder.
[0057] In this case, the blank holder does not make contact with
the intermediate formed product until the outer punch makes contact
with the intermediate formed product at the first step. After the
outer punch makes contact with the intermediate formed product, the
blank holder makes contact with the intermediate formed product at
the second step. Therefore, a temperature drop of the intermediate
formed product before the start of pressing, which is caused by
contact with the blank holder, can be suppressed. Consequently, hot
stamping can be carried out in the final pressing while the
intermediate formed product keeps workability.
[0058] In the first step, the blank holder may be positioned such
that the end surface of the blank holder is at a height lower than
a height of a stair portion of the end surface of the center die
corresponding to the stair of the panel-like formed product.
[0059] In the manufacturing method, the steel plate may be a
tailored blank.
[0060] A panel-like formed product, a vehicle door, and a method
for manufacturing a panel-like formed product according to some
embodiments of the present invention will hereinafter be described
in reference to the drawings. In the drawings, the same parts and
members are provided with the same reference symbols, and the same
descriptions will not be repeated.
[0061] In the following description of the embodiments, a door
inner panel for an automobile side door will be described as an
example of a panel-like formed product. However, panel-like formed
products are not limited to door inner panels for automobile side
doors. Panel-like formed products may be, for example, door inner
panels for rear doors and any other doors as well as side doors.
Also, panel-like formed products are not limited to door inner
panels. Panel-like formed products are usable as members required
to have a good collision property.
[0062] In reference to FIG. 1, a panel-like formed product 1, which
is a door inner panel, includes a top board 2, vertical walls 5,
and a flange 7. In the following description of the panel-like
formed product 1, the direction from the flange 7 toward the top
board 2 will be referred as an upward direction (indicated by arrow
U in FIG. 1), and the direction from the top board 2 toward the
flange 7 will be referred to as a downward direction (indicated by
arrow D in FIG. 1). Further, in FIG. 1, arrow VU and arrow VD
indicate the upward direction and the downward direction,
respectively, of a vehicle in which the panel-like formed product 1
is used as a door inner panel.
[0063] In reference to FIG. 1, the material of the panel-like
formed product is a metal plate. The panel-like formed product 1 is
made by press forming the metal plate, for example.
[0064] In FIG. 1, the metal plate used as the material of the
panel-formed product 1 has a substantially constant plate
thickness. Accordingly, the plate thickness of the entire
panel-formed product 1 is substantially constant. However, the
plate thickness of the panel-formed product 1 may be varied in some
degree due to the press forming. The plate thickness of the
panel-like formed product 1 is 0.3 to 2.3 mm, for example.
[0065] The top board 2 of the panel-like formed product 1 is
polygonal. The top board 2 may be quadrangular or pentagonal, for
example. The top board 2 may be in the shape of a polygon having
more than five sides. In this description, "polygon" includes a
polygonal shape having round corners (corners and vertexes with a
radius of curvature, for example). FIG. 1 shows an example in which
the top board 2 is pentagonal.
[0066] The top board 2 includes a frame portion 3 and a concave
portion 4. The frame portion 3 extends along the outer edge OE of
the top board 2 in at least a part of the outer edge OE. The frame
portion 3 includes some of the sides of the top board 2 defining
the outer edge OE which connect to the vertical walls 5. In FIG. 1,
the frame portion 3 includes sides 2A to 2D, among the sides 2A to
2E defining the outer edge OE, and the sides 2A to 2D connect to
the vertical walls 5. On the side 2E, which is a part of the outer
edge OE and is located farthest in the vehicle upward direction
(indicated by arrow VU), no frame portion 3 and no vertical wall 5
are formed. The side 2E defines what is called a beltline.
[0067] The concave portion 4 is located in an inner portion of the
top board 2, at the inner side of the frame portion 3, and recedes
from the frame portion 3. The concave portion 4 includes a bottom
face 4A and a side surface 4B. The concave portion 4 is to heighten
an impact property against external force (impact) applied mainly
from the up-down direction of the panel-like formed product (mainly
from the direction indicated by arrow U in FIG. 1). This will be
described later. The top board 2 shown in FIG. 1 does not include
any through-holes or other openings. However, the top board 2 may
have through-holes and other openings. When the top board 2 has an
opening, the opening may be to receive any member fitted therein or
alternatively to attain a weight reduction of the panel-like formed
product 1.
[0068] The vertical walls 5 extend from two or more of all the
sides of the top board 2 defining the outer edge OE of the top
board 2. The vertical walls 5 extend in a direction crossing
directions in which the top board 2 spreads. In FIG. 1, the
vertical walls 5 extends in the downward direction of the
panel-like formed product 1 (in the direction indicated by arrow D)
which is perpendicular to the directions in which the top board 2
spreads. In other words, the vertical walls 5 extend
perpendicularly to the top board 2. However, the vertical walls 5
need not extend in the direction perpendicular to the directions in
which the top board 2 spreads and need not extend perpendicularly
to the top board 2.
[0069] The upper ends of the vertical walls 5 connect to the
corresponding sides 2A to 2D. In FIG. 1, the vertical walls 5
extend downward from the sides 2A to 2D. However, it is only
necessary that the vertical walls 5 extend at least two adjacent
sides of all the sides defining the outer edge OE of the top board
2.
[0070] As described above, in the panel-like formed product 1 to be
used as a door inner panel, none of the frame portion 3 and the
vertical walls 5 extends from the side 2E of the top board 2. This
is because the side 2E will be an entry/exit for a window member
when the panel-like formed product 1 is incorporated in a side door
as a door inner panel.
[0071] At least two adjacent vertical walls of the vertical walls 5
include a first vertical wall section 5A, a stair 6 and a second
vertical wall section 5B. Thus, the vertical walls 5 including the
stair 6 has a stair-like shape.
[0072] The first vertical wall section 5A and the second vertical
wall section 5B extend in a direction crossing the directions in
which the top board 2 spreads. The first vertical wall section 5A
and the second vertical wall section 5B may be and need not be
parallel to each other. The first vertical wall section 5A may be
and need not be perpendicular to the top board 2. The second
vertical wall section 5B may and need not be perpendicular to the
top board 2.
[0073] The stair 6 spreads in the directions in which the top board
2 spreads. The stair 6 has an inner edge 6A connecting to the lower
end of the first vertical wall section 5A. The stair 6 has an outer
edge 6B connecting to the upper ends of the second vertical wall
section. The stair 6 shown in FIG. 1 has a substantially flat
surface. However, the surface of the stair 6 need not be strictly
flat and may have asperities in some degree. The directions in
which the stair 6 spreads may be and need not be parallel to the
directions in which the top board 2 spreads. Preferably, the
curvatures of the asperities of the surface of the stair 6 are less
than 0.01.
[0074] The flange 7 connects to the lower end of the second
vertical wall section 5B of the vertical walls 5. The flange 7
spreads in the directions in which the top board 2 spreads. The
direction in which the flange 7 spreads may be and need not be
parallel to the direction in which the top board 2 spreads.
[0075] In FIG. 1, four adjacent vertical walls 5 are in a
stair-like shape and include a stair 6. In the case shown in FIG.
1, there are three pairs of adjacent vertical walls 5 (a pair
formed of the vertical wall 5 connecting to the side 2A and the
vertical wall 5 connecting to the side 2B, a pair formed of the
vertical wall 5 connecting to the side 2B and the vertical wall 5
connecting to the side 2C, and a pair formed of the vertical wall 5
connecting to the side 2C and the vertical wall 5 connecting to the
side 2D), and these three pairs of vertical walls 5 include the
stair 6. However, the number of pairs of vertical walls 5 including
the stair 6 is not limited to three. In the panel-like formed
product 1, it is only necessary that at least one of the pairs of
adjacent vertical walls (that is, at least two adjacent vertical
walls 5) includes the stair 6.
[0076] In the case shown in FIG. 1, the stair-like vertical walls 5
include only one stair 6. However, the number of stairs 6 is not
limited to one, and the stair-like vertical walls may include a
plurality of stairs 6. In other words, the vertical walls 5 may be
in a stair-like shape including a plurality of stairs. In this
case, the lower end of the second vertical wall section 5B connects
to the inner edge of the flange 7, and the upper end of the second
vertical wall section 5B connects to the outer edge of the bottom
stair 6. The inner edge of the bottom stair 6 connects to the lower
end of the first vertical wall section 5A. Above the first vertical
wall section 5A, the other parts of the stairs (at least one other
stair and other vertical walls) are formed.
[0077] The top board 2 of the panel-like formed product 1 according
to the present invention, as mentioned above, includes a concave
portion 4, which recedes from the edge 3, at the inner side of the
edge 3. Because of the concave portion 4, the panel-like formed
product 1 has an excellent collision property. This will be
described below.
[0078] FIG. 2 is a sectional view of a standard automobile side
door along a line perpendicular to the vehicle up-down direction.
The side door is produced by fitting a door inner panel A and a
door outer panel 100 together. A space SP is formed between the
door outer panel A and the door inner panel 100. In the space SP,
an audio speaker, a window, a window drive device, and the like are
set.
[0079] When the automobile has a side-impact crash, a load P
(indicated by an outlined arrow in FIG. 2) is applied to the door
outer panel A. Then, the door outer panel A is deformed by the load
P, and the vertical wall 500 of the inner panel 100 is deformed.
The deformation of the vertical wall 500 of the door inner panel
100 absorbs the collision energy by the load P. Therefore, in order
to improve the collision property of the side door, it is necessary
to improve the collision property of the door inner panel.
[0080] However, the conventional door inner panel 100 is made of a
soft steel plate with low strength. The reason is as follows. As
described above, the door inner panel has a complicated shape, and
it is difficult to press a steel plate with high strength into the
shape of the door inner panel 100. A soft steel plate has a tensile
strength of not more than 330 MPa, for example. Therefore, in a
conventional automobile side door made of a soft steel plate,
usually, a reinforcing member 101, which is a different part from
the door inner panel 100, is disposed between the door outer panel
A and the door inner panel 100, as shown in FIG. 2. Thereby, the
collision property of the side door is improved. The reinforcing
member 101 is, for example, a beltline reinforcement, a door impact
beam, or the like.
[0081] In reference to FIG. 2, in the side door with the
reinforcing member 101, when the door outer panel A is deformed
inward by the load P, the deformed door outer panel A first hits
against the reinforcing member 101. Accordingly, the collision
energy is absorbed by the reinforcing member 101 in addition to by
the door inner panel 100. Thus, the collision property of the side
door is improved.
[0082] On the other hand, when the panel-like formed product 1
according to the embodiment is employed in a vehicle door as a door
inner panel, it is possible to improve the collision property of
the vehicle door without using the reinforcing member 101. FIG. 3
is a sectional view of a vehicle door, in which the panel-like
formed product 1 according to the embodiment is employed, along a
line perpendicular to the vehicle up-down direction. FIG. 3 shows a
case in which the vehicle door is a side door to be attached to a
side of a vehicle.
[0083] In reference to FIG. 3, the vehicle door includes the
panel-like formed product 1 employed as a door inner panel, a door
outer panel A, and a window member 8. The window member 8 is a
transparent member, and for example, is a window glass. The window
member 8 may be made of transparent resin, for example.
[0084] The door outer panel A is located in an outer portion of the
vehicle, at the outer side of the panel-like formed product 1. The
panel-like formed product 1 is located in an inner portion of the
vehicle, at the inner side of the door outer panel A. The
panel-like formed product 1 is joined with the door outer panel A.
Specifically, the flange 7 of the panel-like formed product 1 is
joined with the door outer panel A. In this regard, the concave
portion 4 of the panel-like formed product 1 projects toward the
door outer panel A. The window member 8 is positioned such that at
least a part of the window member 8 can be housed in the concave
portion 4.
[0085] As described above, in the panel-like formed product 1, the
concave portion 4 receding from the edge 3 is formed in the top
board 2. Accordingly, when the panel-like formed product 1 is
joined with the door outer panel A, the bottom face 4A of the
concave portion 4 is positioned near the door outer panel A as
shown in FIG. 3. Therefore, when the door outer panel A is deformed
inward by collision, the door outer panel A hits against the
concave portion 4. Then, the collision energy is absorbed not only
by the vertical walls 5 but also by the concave portion 4. Hence,
the panel-formed product 1 is difficult to deform, and the
collision property of the panel-formed product 1 and the side door
is improved.
[0086] Thus, the concave portion 4 of the panel-like formed product
1 according to the embodiment can substitute for the reinforcing
member 101 shown in FIG. 2. Therefore, the side door with the
panel-like formed product 1 has an excellent collision property
though not having the reinforcing member 101.
[0087] The material of the panel-like formed product 1 shown in
FIG. 1 is a steel plate. However, the material of the panel-like
formed product 1 is not limited to a steel plate and may be any
other metal plate. The metal plate usable as the material is, for
example, a plate of aluminum, an aluminum alloy, titanium,
magnesium, or the like.
[0088] The shape of the panel-like formed product is complicated as
described above. Therefore, when the panel-like formed product 1 is
made of a steel plate by a conventional pressing method, wrinkles
and other defects are likely to be generated. However, by adopting
a manufacturing method as described below, it is possible to
manufacture the panel-like formed product 1 while suppressing
generation of wrinkles and other defects. Further, by carrying out
hot stamping as described below, it is possible to manufacture a
panel-like formed product 1 with a tensile strength of not less
than 600 MPa, and preferably not less than 1200 MPa, from a steel
plate. Accordingly, the concave portion 4 can fully substitute for
the reinforcing member 101. For reference, when a final pressing
step to be described later is carried out as cold pressing, the
panel-like formed product 1 made of a steel plate has a tensile
strength of not less than 340 MPa, for example.
[0089] When the material of the panel-like formed product according
to the present invention is a steel plate, it is preferred that the
microstructure of the steel plate includes martensite. More
desirably, the microstructure of the steel plate includes
martensite as a base. As mentioned above, the tensile strength of
the steel plate is desirably not less than 600 MPa, and more
desirably not less than 1200 MPa. The Vickers hardness of the steel
plate is desirably not less than HV180, and more desirably not less
than HV380. The tensile strength is measured in conformity with JIS
Z 2241 (2011), and the Vickers hardness is measured in conformity
with JIS Z 2244 (2009).
[0090] Here, the sentence, "the microstructure of the steel plate
includes martensite as a base" means that the microstructure of the
steel plate includes martensite at 70% or more in area ratio. The
area ratio of martensite in the microstructure is desirably not
less than 80%, more desirably not less than 90%, still more
desirably 95%, and most desirably 100%. The martensite in the
microstructure may be tempered martensite. By adjusting the area
ratio of martensite in the microstructure and the tempering
condition (tempering temperature) appropriately by a conventional
method, it is possible to cause the panel-like formed product to
have a tensile strength of not less than 600 MPa.
[0091] When the material of the panel-like formed product is a
steel plate, the steel plate has a chemical composition, for
example, including, in mass %, C: 0.11 to 0.50%, Si: 0.15 to 0.25%,
Mn: 0.08 to 1.50%, B: 0 to 0.0030, and Cr: 0 to 0.25%. The chemical
composition may, for example, include, in mass %, C: 0.11 to 0.50%,
Si: 0.15 to 0.25%, Mn: 0.08 to 1.50%, B: 0 to 0.0030%, and Cr: 0 to
0.25%, the balance being Fe and impurities. The steel plate may
contain either B: 0.0020 to 0.0030% or Cr: 0.15 to 0.25%, or
both.
[0092] As described above, the microstructure of the steel plate
used as the material of the panel-like formed product includes
martensite. The microstructure is formed by hot stamping. The steel
plate usable as the material of the panel-like formed product does
not. necessarily have the above-described chemical composition, and
any steel plate is usable as long as it has a microstructure
including martensite.
[0093] When the panel-like formed product 1 is used as a door inner
panel, typically, the panel-like formed product 1 has the following
dimensions.
[0094] Entire length (including the flange 7): 800 to 1300 mm
[0095] Entire width (including the flange 7): 600 to 800 mm
[0096] Entire length of the top board 2: 700 to 1200 mm
[0097] Entire width of the top board 2: 500 to 700 mm
[0098] Height of the first vertical wall section 5A: 30 to 100
mm
[0099] Height of the second vertical wall section 5B: 30 to 100
mm
[0100] Minimum width of the stair: 20 to 40 mm
[0101] Plate thickness of the material steel plate: 0.3 to 2.3 mm
(preferably 0.5 to 1.8 mm)
[0102] The frame portion 3 of the panel-like formed product 1
preferably has a width W (unit: mm, see FIG. 1) which satisfies the
condition expressed by the following formula (1), in which L
denotes the maximum width (mm) of the top board 2. The maximum
width L of the top board 2 (including the frame portion 3 and the
concave portion 4) means the largest distance among every distance
between any two points on the outer edge OE of the top board 2.
10<W<0.2.times.L (1)
[0103] When the panel-like formed product 1 is used as a door inner
panel of an automobile side door, the maximum width L of the top
board 2 is the dimension of the top board 2 in the vehicle
front-rear direction.
[0104] When the width W of the frame portion 3 is greater than 10
mm, the frame portion 3 is wide enough. Accordingly, the strength
of the vertical walls 5, including the strength of the frame
portion 3, is high, and the vertical walls 5 are unlikely to fall
when a collision load is applied thereto. When the width W of the
frame portion 3 is less than 0.2.times.L, the concave portion 4 is
large enough. In this case, the concave portion 4 sufficiently
absorbs the collision energy and fully substitutes for the
reinforcing member 104. The width W of the frame portion 3 is
preferably as small as possible within the range expressed by the
formula (1). Also, the width W of the frame portion 3 is preferably
constant across the entire length. This is to ensure a sufficient
area for the concave portion 4 of the top board 2.
[0105] In reference to FIG. 3, the distance H between the frame
portion 3 and the bottom face 4A (which corresponds to the height
of the side surface 4B and will hereinafter be also referred to as
the height of the concave portion 4) is preferably greater than the
distance H1 between the frame portion 3 and the stair 6 (which will
hereinafter be referred to as the height of the stair 6). In this
case, when the panel-like formed product 1 is used in a side door,
the bottom face 4A of the concave portion 4 is positioned near the
door outer panel A. Accordingly, when the door outer panel A is
deformed inward of the vehicle by impact, the concave portion 4
hits against the door inner panel A at an early stage. Therefore,
when the panel-like formed product 1 is used as a door inner panel,
the collision property of the door is improved.
[0106] In reference to FIG. 3, the distance H0 between the surface
of the frame portion 3 and the surface of the flange 7 is defined
as the entire height H0 of the panel-like formed product 1. In this
case, the height H1 (mm) of the stair 6 satisfies the condition
expressed by the following formula (2).
0.25.times.H0<H1<H (2)
[0107] When the panel-like formed product 1 is used as a door inner
panel, the stair 6 faces a pillar B or the like of the vehicle body
and seals the inside of the vehicle (see FIG. 3). In order to seal
the inside of the vehicle tighter, a sealing member is provided
between the stair 6 and the pillar B or the like.
[0108] When the height H1 of the stair 6 is sufficiently greater
than 0.25.times.H0, a sufficient height is secured for the second
vertical wall section 5B. In this case, a sufficient area is
secured for the sealing member to be attached to the second
vertical wall section 5B, and the inside of the vehicle can be
sealed tighter.
[0109] The position of the concave portion 4 is preferably as close
as possible to the door outer panel A. As shown in FIG. 3, the
window member 8 is set in an inner portion of the vehicle, at the
inner side of the panel-like formed product 1, and is housed in the
concave portion 4 of the panel-like formed product 1. Accordingly,
as shown in FIG. 3, the bottom face 4A of the concave portion 4
intervenes between the door outer panel A and the window member
8.
[0110] The structure of the side door in which the panel-like
formed product 1 is used is not limited to the structure shown in
FIG. 3. The window member 8 and other parts may be disposed between
the panel-like formed product 1 and the door outer panel A. The
height H of the concave portion 4 is determined in consideration of
the material and the workability of the workpiece to be subjected
to forming. Then, the position of the window member 8 is determined
in consideration of the height H of the concave portion 4.
[0111] FIG. 4 is a perspective view of another panel-like formed
product 10 according to the embodiment which is different from the
panel-like formed product shown in FIG. 1. In reference to FIG. 4,
the panel-like formed product 10 includes a concave portion 4 as
the panel-like formed product 1, and the panel-like formed product
10 further includes one or more depressions 11 in the bottom face
4A of the concave portion 4.
[0112] The depression 11 is, for example, formed linearly in the
bottom face 4A of the concave portion 4. The "linearly" means in
the shape of a straight line, a curved line, a wavy line, or the
like. There are no other differences in structure between the
panel-like formed product 10 and the panel-like formed product 1
shown in FIG. 1. The panel-like formed product 10 with the
depression 11 in the bottom face 4A of the concave portion 4 will
hereinafter be described.
[0113] When the depression 11 is formed in the bottom face 4A, the
bottom face 4A with the depression 11 increases in second moment of
area. In other words, the depression 11 increases the strength of
the concave portion 4 of the panel-like formed product 10.
Accordingly, the concave portion 4 with the depression 11 absorbs
more collision energy. It is especially preferred that the
depression 11 is formed in a vehicle upper area 12 including the
beltline (side 2E) of the concave portion 4 (the vehicle upper area
hereinafter being referred as a "beltline area"), along the
beltline area 12. In other words, the depression 11 is formed in
the bottom face 4A, preferably near and along the side 2E defining
the beltline. In this case, when the panel-like formed product 1 is
used as a door inner panel, the beltline is reinforced. Thus, the
depression 11 functions as a beltline reinforcement.
[0114] As shown in FIG. 4, the depression 11 may be formed in the
bottom face 4A of the concave portion 4, diagonally from the side
2E defining the beltline. In this case, the depression 11
reinforces the entire bottom face 4A of the concave portion 4. A
projection may be formed on the bottom face 4A of the concave
portion 4 instead of the depression 11. Both the depression 11 and
the projection may be formed. The depression 11 and/or the
projection formed in/on the bottom face 4A of the concave portion 4
increase the second moment of area of the concave portion 4.
[0115] As an example of a panel-like formed product according to
the embodiment, a side door inner panel has been described.
However, the panel-like formed product according to the embodiment
is not limited to a side door inner panel. The panel-like formed
product according to the embodiment can be used as a door inner
panel for a rear door or any other door as well as a side door. The
panel-like formed product according to the embodiment is not
limited to a door inner panel. The panel-like formed product can be
used as a member which is required to have a high collision
property. Such a member is usable in an automobile, a railcar, a
self-propelled construction machine, a self-propelled agricultural
machine, a self-propelled industrial machine, an air vehicle, or
the like, and is especially suited for use as a door of such a
vehicle.
[0116] In the above-described embodiment, the steel plate used as
the material of the panel-formed product 1 may be a tailored blank.
Tailored blanks are generally classified into tailored welded
blanks (which will hereinafter be referred to also as "TWB"s) and
tailored rolled blanks (which will hereinafter be referred to also
as "TRB"s). A TWB is produced by joining different kinds of steel
plates which are different in plate thickness, tensile strength,
etc. together by welding (for example, by butt welding). A TRB is a
steel plate with various plate thicknesses produced by use of
reduction rolls arranged at irregular intervals. By using a
tailored blank, it is possible to increase the strength of only a
desired part, and it is possible to decrease the plate thickness. A
panel-like formed product made of a tailored blank is suited for
use as a vehicle door inner panel. Thereby, the collision property
can be improved, and a further weight reduction can be
expected.
[0117] As described above, the panel-like formed product 1
according to the embodiment includes a concave portion 4 in the top
board 2, at the inner side of the frame portion 3. Because of the
concave portion 4, the panel-like formed product 1 has a shape into
which a conventional door inner panel and a conventional
reinforcing member as typified by a door impact beam are unified.
Therefore, the panel-like formed product 1 has an excellent
collision property with no need to provide a door impact beam and
any other reinforcing member 101.
[0118] It is preferred that the panel-like formed product according
to the embodiment has high strength. The tensile strength of the
panel-like formed product is desirably not less than 600 MPa and
more desirably not less than 1200 MPa. When the panel-like formed
product has higher tensile strength, the door inner panel using the
panel-like formed product can absorb more collision energy.
However, when a steel plate is used as the material of the
panel-like formed product, it is difficult to produce a high
strength panel-like formed product by press forming. When a
high-strength steel plate is used as the material, the
high-strength steel plate has low workability, and therefore, it is
difficult to form the panel-like formed product 1 with a
complicated shape by press forming.
[0119] However, by adopting a panel-like formed product
manufacturing method according to an embodiment as described below,
it is possible to produce a panel-like formed product 1 with high
strength even when using a steel plate as the material. An
exemplary method for manufacturing a panel-like formed product from
a steel plate will be described below.
[Manufacturing Method]
[0120] A manufacturing method according to an embodiment of the
present invention includes a preparing step, an intermediate
pressing step, a heating step, and a final pressing step. According
to the embodiment, hot stamping is carried out in the final
pressing step. The respective steps will be described. However,
when the final pressing step is executed as cold pressing, the
heating step is not carried out. The case in which the final
pressing step is executed as cold pressing will be described
later.
[Preparing Step]
[0121] In the preparing step, a planar blank made of a steel plate
is prepared. There is no particular limit to the chemical
composition of the steel plate as a blank as long as a
microstructure including martensite is formed therein by hot
stamping which will be described below. The chemical composition
preferably contains carbon (C) at not less than 0.11% in weight
percent. When the steel plate contains C at not less than 0.11%,
the panel-like formed product after the hot stamping step will have
high strength. The steel plate more desirably has a chemical
component as described above in connection with the panel-like
formed product 1.
[0122] The steel plate as a blank may be a surface-treated steel
plate. The surface-treated steel plate is, for example, a
zinc-plated steel plate with a zinc plating on the surface. The
blank may have an opening and need not have an opening.
[Intermediate Pressing Step]
[0123] In the pressing step, the blank is subjected to cold, warm,
or hot pressing, and thereby, an intermediate formed product 1.A as
shown in FIG. 5 is produced.
[0124] As show in FIG. 5, in the intermediate formed product 1A, as
compared with the panel-like formed product 1, the top board 2 has
been formed, and the first vertical wall section 5A has been formed
to a height H1 of an intermediate flange 7A which corresponds to
the stair C. Specifically, the intermediate formed product 1A
includes a top board 2, a first vertical wall section 5A, and an
intermediate flange 7A. The first vertical wall section 5A is
located between the top board 2 and the intermediate flange 7A. A
first end of the first vertical wall section 5A connects to the
outer edge of the top board 2, and a second end thereof connects to
the intermediate flange 7A. The first vertical wall section 5A
extends in a direction crossing the directions in which the top
board 2 spreads. The intermediate flange 7A spreads from the second
end of the first vertical, wall section 5A in the directions in
which the top board spreads. The intermediate flange 7A may be and
need not be parallel to the direction in which the top board 2
spreads. The distance from the surface of the frame portion 3 to
the surface of the intermediate flange 7A is equal to the distance
H1 from the surface of the frame portion 3 to the surface of the
stair 6 in the panel-like formed product 1.
[0125] The first vertical wall section 5A corresponds to the first
vertical wall section 5A of the panel-like formed product 1 as a
final product. The intermediate flange 7A includes the stair 6 of
the panel-like formed product 1 as a final product. Thus, the
intermediate formed product 1A is an intermediate product obtained
in the middle of production of the panel-like formed product 1 and
before forming of the second vertical wall section 5B, the stair 6
and the flange 7.
[0126] In the intermediate pressing step, first, a concave portion
4 is formed in the blank (first intermediate pressing step). Next,
while the concave portion 4 is pinched by dies, the frame portion
3, the first vertical wall section 5A and the intermediate flange
7A are formed (second intermediate pressing step). In the
intermediate pressing step, the blank is pressed such that the top
board 2 is formed and such that the vertical wall section 5A is
formed to the height of the stair 6, and thereby, the intermediate
formed product 1A is produced.
[0127] In producing the intermediate formed product 1A, in the
second intermediate pressing step, while the concave portion 4 is
pinched and held between dies (a punch and a die), the first
vertical wall section 5A and the flange 7A are formed. This reduces
the risk of causing wrinkles and other defects due to press
forming. Two embodiments (a first embodiment and a second
embodiment) of the intermediate pressing step will be described
below. In the first embodiment, the first and the second
intermediate pressing steps are carried out by use of the same dies
(a punch and a die). In the second embodiment, different dies
(punches and dies) are used in the first intermediate pressing step
and in the second intermediate pressing step. The respective
embodiments will be described below.
First Embodiment
[0128] FIGS. 6A to 6C are sectional views schematically showing an
intermediate pressing step according to the first embodiment. FIG.
6A shows a step of placing a blank S in an intermediate pressing
machine 20 (blank placing step). FIG. 6B shows a step of forming
the concave portion 4 by pressing (first intermediate pressing
step). FIG. 6C shows a step of forming the first vertical wall
section 5A and the intermediate flange 7A by pressing (second
intermediate pressing step).
[0129] In the intermediate pressing step according to the first
embodiment, the intermediate pressing machine 20 shown in FIG. 6A
is used. The intermediate pressing machine 20 includes a center
punch 21, an intermediate punch 21 and an outer pinch 23 as upper
dies, and includes a center die 24 and a blank holder 25 as lower
dies. The upper dies engage with the lower dies.
[0130] The punch end surface (end surface to press the blank S for
forming) of the center punch 21 has a shape corresponding to the
concave portion 4 of the intermediate formed product 1A.
Specifically, the punch end surface and a nearby part of the side
surface of the center punch 21 have shapes corresponding to the
shapes of the bottom face and the side surface of the concave
portion 4.
[0131] The center punch 22 is located at the outer side of the
center punch 21 and at the inner side of the outer punch 23. The
punch end surface of the intermediate punch 22 has a shape
corresponding to the shape of the frame portion 3 of the top board
2. There is a clearance between the intermediate punch 22 and the
center punch 21.
[0132] The outer punch 23 is located at the outer side of the
intermediate punch 22 and adjacent to the intermediate punch 22.
There is a clearance between the outer punch 23 and the
intermediate punch 22.
[0133] The die end surface (end surface to contact the blank S) of
the center die 24 faces the punch end surface of the center punch
21 and the punch end surface of the intermediate punch 22. The die
end surface of the center die 24 has a shape corresponding to the
shape of the top board 2. Specifically, the die end surface of the
center die 24 includes a concave portion 24A corresponding to the
concave portion 4 and a frame portion 24B corresponding to the
frame portion 3.
[0134] The blank holder 25 is located at the outer side of the
center die 24 and adjacent to the center die 24. There is a
clearance between the blank holder 25 and the center die 24. The
end surface of the blank holder 25 faces the punch end surface of
the outer punch 23. The blank holder 25 is used to form the first
vertical wall section 5A and the intermediate flange 7A.
[0135] In reference to FIG. 6A, the center punch 21, the
intermediate punch 22 and the outer punch 23 are supported by an
upper holder 26. The center punch 21, the intermediate punch 22 and
the outer punch 23 are movable (movable up and down) relative to
one another. For example, a pressing member (not shown) may be
disposed between the intermediate punch 22 and the upper holder 26,
and a pressing member (not shown) may be disposed between the outer
punch 23 and the upper holder 26. The pressing members are, for
example, hydraulic cylinders, gas cylinders, springs, rubber
members, or the like.
[0136] Only one pressing member may be provided for the vertical
motions of the intermediate punch 22 and the outer punch 23
relative to the center punch 21, or alternatively separate pressing
members may be provided for the intermediate punch 22 and the outer
punch 23, respectively, as described above. A pressing member (not
shown) may be disposed between the center punch 21 and the upper
holder 26. There is no particular limit to the mechanism for
vertical motions of the center punch 21, the intermediate punch 22
and the outer punch 23 as long as it allows these punches to move
up and down independently of one another and relative to one
another.
[0137] The center die 24 and the blank holder 25 are supported by a
lower holder 27. The blank holder 25 is movable up and down
relative to the center die 24. For example, a pressing member (not
shown) is disposed between the blank holder 25 and the lower holder
27. The pressing member may be as described above.
[0138] The upper holder 26 is fastened to a lifting and lowering
device (slide) (not shown). The lifting and lowering device is
driven to move up or down the upper holder 26. The lower holder 27
is fastened to a bolster plate (not shown).
[0139] The intermediate pressing machine 20 are not limited to the
structure shown in FIG. 6A as long as it includes the center punch
21, the intermediate punch 22, the outer punch 23, the center die
24 and the blank holder 25. For example, the center punch 21, the
intermediate punch 22 and the outer punch 23 may be fastened to
separate slides which are independently movable up and down.
[0140] The intermediate pressing step by use of the intermediate
pressing machine 20 will be described in detail below. First, as
shown in FIG. 6A, the planar blank S is placed between the upper
dies and the lower dies of the intermediate pressing machine 20. In
this regard, the punches are positioned such that the punch end
surface of the upper center punch 21, the punch end surface of the
intermediate punch 22 and the punch end surface of the outer punch
23 are substantially on the same level with one another. In other
words, the punch end surfaces of the punches 21 to 23 are
positioned to be substantially at the same height with one another.
Similarly, the frame portion 24B of the center die 24 and the end
surface of the blank holder 25 are positioned to be substantially
on the same level with each other. In other words, the frame
portion 24B of the center die 24 and the end surface of the blank
holder 25 are positioned to be substantially at the same height
with each other. Accordingly, the blank S is placed on the center
die 24 and the blank holder 25 to contact the frame portion 24B of
the center die 24 and the end surface of the blank holder 25.
[0141] Next, the first intermediate pressing step is carried out.
Specifically, the lifting and lowering device (slide) is driven to
lower the upper holder 26. For example, the punches 21 to 23 are
lowered with the end surfaces of the punches 21 to 23 kept at the
same height with one another until the punches 21 to 23 make
contact with the upper surface of the blank S.
[0142] The upper holder 26 is lowered, and the center punch 21, the
intermediate punch 22 and the outer punch 23 make contact with the
upper surface of the blank S. Then, the blank S is pinched and held
between the punch end surface of the center punch 21 and the frame
portion 24B of the center die 24. The blank S is also pinched and
held between the punch end surface of the outer punch 23 and the
end surface of the blank holder 25.
[0143] Further, the blank S is pinched between the intermediate
punch and the frame portion 24B of the center die 24. The center
punch 21 is moved further down relative to the intermediate punch
22 and the outer punch 23 while the blank S is pinched between the
outer punch 23 and the blank holder 25, and thus, the concave
portion 4 is formed in the blank S by pressing (drawing) (see FIG.
6B).
[0144] On completion of the forming of the concave portion 4, the
concave portion 4 of the blank S is pinched and held between the
punch end surface of the center punch 21 and the concave portion
24A of the center die 24. In other words, on completion of the
first intermediate pressing step, the blank S is pinched between
the punches 21 to 23 and the center die 24 and the blank holder
25.
[0145] Next, the second intermediate pressing step is carried out
to form the first vertical wall section 5A and the intermediate
flange 7A, and, thereby, the intermediate formed product 1A is
produced. Specifically, while the blank S is pinched between the
center and intermediate punches 21 and 22 and the center die 24 and
is pinched between the outer punch 23 and the blank holder 25, the
outer punch 23 and the blank holder 25 are moved down relative to
the center and the intermediate punches 21 and 22 and the center
die 24 to press the blank S (see FIG. 6C). Thereby, the first
vertical wall section 5A and the intermediate flange 7A are formed
in the blank S, and the blank S is formed into the intermediate
formed product 1A.
[0146] In the intermediate pressing step, the concave portion 4 is
formed at the first intermediate pressing step, and the frame
portion 3A, the first vertical wall section 5A and the intermediate
flange 7A, which are to be positioned at the outer side of the
concave portion 4, are formed at the second intermediate pressing
step. If the first vertical wall section 5A and the intermediate
flange 7A are formed before the forming of the concave portion 4,
in the inner portion of the blank S than the first vertical wall
section 5A, the material will be tense. If the center punch 21 is
moved down while the material is tense, the amount of material to
be drawn into the concave portion 24A of the center die 24 will be
insufficient. This means that the amount of material for forming of
the concave portion 4A is inadequate. This may cause variation of
the concave portion 4 of the intermediate formed product 1 in plate
thickness, and/or may cause cracks in the concave portion 4. In the
intermediate pressing step according to the embodiment, the concave
portion 4 is formed at the first intermediate pressing step, and
thereafter, the frame portion 3, the first vertical wall section 5A
and the intermediate flange 7A, which are to be positioned at the
outer side of the concave portion 4, are formed at the second
intermediate pressing step. In this case, in the intermediate
pressing step, there is an adequate amount of material that can be
drawn into the concave portion 24A of the center die 24. Therefore,
the concave portion 24 is easily formed. After the forming of the
concave portion 4 at the first intermediate pressing step, the
blank S is pressed by the outer punch 23 and the blank holder 25
while the blank S with the concave portion 4 formed therein is
pinched and held between the intermediate punch 22 and the center
die 24, and thereby, the first vertical wall section 5A and the
intermediate flange 7A are formed. Thus, the intermediate formed
product 1 is produced. This process suppresses generation of
wrinkles, cracks and other defects in the intermediate formed
product 1A.
[0147] In FIG. 6A, when the center punch 21, the intermediate punch
22 and the outer punch 23 make contact with the upper surface of
the blank S, the gap between the punch end surface of the
intermediate punch 22 and the end surface of the frame portion 24B
of the center die 24 and the gap between the punch end surface of
the outer punch 23 and the end surface of the blank holder 25 are
preferably of a size corresponding to the plate thickness of the
blank S plus an additional space of about 0.1 mm (more
specifically, for example, 0.05 to 0.3 mm). The gap size can be
achieved in a structure as follows, for example. One or more
spacers (not shown) are attached to a part of the outer edge of the
frame portion 24B of the center die 24 and/or a part of the outer
edge of the end surface of the blank holder 25. The spacers have a
thickness corresponding to the gap size, and the spacers contact
the punch end surface of the intermediate punch 22 and/or the punch
end surface of the outer punch 23. Therefore, the blank S is
pinched loosely and held in the gap between the punch end surface
of the intermediate punch 22 and the end surface of the frame
portion 24B of the center die 24 and between the punch end surface
of the outer punch 23 and the end surface of the blank holder 25.
Accordingly, in forming the concave portion 4 at the first
intermediate pressing step, it is easy to draw the material into
the concave portion 24A of the center die 24. The same applies to
FIG. 6B. However, when the additional spaces increase the risk of
causing wrinkles, it is not necessary to make the additional
spaces, and a pinching force may be applied to the blank S within a
degree not to cause wrinkles.
Second Embodiment
[0148] In the first embodiment, the first pressing step and the
second pressing step are carried out by use of the same one
intermediate pressing machine 20. However, different intermediate
pressing machines (different dies) may be used in the first
intermediate pressing step and in the second intermediate pressing
step to form the blank S into the intermediate formed product 1.
The intermediate pressing step according to the second embodiment
in which two intermediate pressing machines are used will
hereinafter be described.
[0149] The intermediate pressing step according to the second
embodiment, as in the first embodiment, includes a first
intermediate pressing step and a second intermediate pressing
step.
[0150] FIG. 7A is a schematic view of a first intermediate pressing
machine 30 used in the first intermediate pressing step. In
reference to FIG. 7A, the first intermediate pressing machine 30 is
a standard pressing machine. The first intermediate pressing
machine 30 includes a center punch 31 and a blank holder 32 as
upper dies, and includes a die 32 as a lower die.
[0151] The punch end surface of the center punch 31 has a shape
corresponding to the bottom face 4A of the concave portion 4 of the
top board 2 of the intermediate formed product 1A. The part of the
punch side surface of the center punch 31 adjacent to the punch end
surface has a shape corresponding to the side surface 4B of the
concave portion 4 of the top board 2.
[0152] The blank holder 33 is located at the outer side of the
center punch 31 and adjacent to the center punch 31. The center
punch 31 and the blank holder 33 are supported by an upper holder
34. A pressing member (not shown) is disposed between the blank
holder 33 and the upper holder 34, and the blank holder 33 is
supported by the upper holder 34 via the pressing member in such a
way as to be movable up and down relative to the center punch 31.
The pressing member is of the same type as the pressing members
provided in the intermediate pressing machine 20 according to the
first embodiment.
[0153] The upper holder 34 is fastened to a lifting and lowering
device (slides) (not shown). The center punch 31 and the blank
holder 33 may be fastened to different slides which are movable up
and down independently of each other.
[0154] The die 32 has an opening in the end surface, in a portion
facing the end surface of the center punch 31. The end surface of
the die 32 except for the opening faces the end surface of the
blank holder 33. The die 32 is supported by a lower holder 35.
[0155] In the intermediate pressing step according to the second
embodiment, first, a blank S is placed on the end surface of the
die 32 of the first intermediate pressing machine 30 (blank placing
step). In this regard, the blank S is placed between the center
punch 31 and the blank holder 33, and the die 32.
[0156] At the time, for example, the end surface of the center
punch 31 and the end surface of the blank holder 33 is
substantially on the same level with each other. In other words,
the end surface of the center punch 31 and the end surface of the
blank holder 33 are substantially at the same height with each
other.
[0157] Next, the first intermediate pressing step is carried out.
The upper holder 34 is lowered by the slide (not shown). The upper
holder 34 is lowered, and the end surface of the center punch 31
and the end surface of the blank holder 33 are brought into contact
with the blank S (see FIG. 7B). Then, the blank S is pinched
between the blank holder 33 and the die 32.
[0158] After the blank S has been pinched between the blank holder
33 and the die 32, the upper holder 34 is moved further down
relative to the blank holder 33. Then, while the blank holder 33 is
holding the blank S, the center punch 31 is moved further down onto
the blank S to form the concave portion 4 (see FIG. 7C). In the
first intermediate pressing step according to the second
embodiment, the blank S is pressed by the above-described
conventional method. Any detailed description of the motions of the
die 32 and the blank holder 33 are not given.
[0159] After the concave portion 4 is formed in the blank S at the
first intermediate pressing step, the second intermediate pressing
step is carried out. FIGS. 8A to 8C are sectional views showing the
second intermediate pressing step according to the second
embodiment. FIG. 8A shows a step of placing the blank S with the
concave portion 4 in a second intermediate pressing machine 40.
FIG. 8B shows a step of pinching the blank S with the concave
portion 4. FIG. 8C shows a step of forming the intermediate formed
product 1A.
[0160] In reference to FIG. 8A, the second intermediate pressing
machine 40 includes a center punch 41 and an outer punch 42 as
upper dies, and includes a center die 43 and a blank holder 44 as
lower dies.
[0161] The punch end surface of the center punch 41 has a shape
corresponding to the shape of the top board 2 (the concave portion
4 and the frame portion 3) of the intermediate formed product 1A.
The outer punch 42 is located at the outer side of the center punch
41 and adjacent to the center punch 41. There is a clearance
between the outer punch 42 and the center punch 41. In this
example, the end surface of the outer punch 42 is flat.
[0162] The end surface of the center die 43 has a shape
corresponding to the shape of the top board 2 (the concave portion
4 and the frame portion 3) of the intermediate formed product 1A,
and the part of the side surface of the center die 43 connecting to
the end surface has a shape corresponding to the first vertical
wall section 5A of the intermediate formed product 1A. The end
surface of the center die 43 faces the punch end surface of the
center punch 41. The blank holder 44 is located at the outer side
of the center die 43 and adjacent to the center die 43. There is a
clearance between the blank holder 44 and the center die 43. In
this example, the end surface of the blank holder 44 is flat and
the end surface faces the end surface of the outer punch 42.
[0163] As shown in FIG. 8A, the center punch 41 and the outer punch
42 are supported by an upper holder 45. A pressing member (not
shown) is disposed between the center punch 41 and the upper holder
45. The pressing member is of the same type as the pressing members
in the first embodiment. The center punch 41 is supported by the
upper holder 45 in such a way as to be movable up and down relative
to the outer punch 42. The upper holder 45 is fastened to a lifting
and lowering device (slide) (not shown).
[0164] The center die 43 and the blank holder 44 are supported by a
lower holder 46. A pressing member (not shown) is disposed between
the blank holder 44 and the lower holder 46. The blank holder 44 is
supported by the lower holder 46 in such a way as to be movable up
and down relative to the center die 43.
[0165] The structure of the second intermediate pressing machine 40
is not limited to that shown in FIG. 8A. In the second intermediate
pressing machine 40, for example, the center punch 41 and the outer
punch 42 may be fastened to different slides which are movable up
and down independently of each other.
[0166] As shown in FIG. 8A, the blank S with the concave portion 4
is placed on the center die 43 and the blank holder 44 of the
second intermediate pressing machine 40. In this regard, the
concave portion 4 that was formed in the blank S at the first
intermediate pressing step is brought into contact with the part of
the end surface of the center die 43 corresponding to the concave
portion 4. The part of the end surface of the center die 43
corresponding to the frame portion 3 and the end surface of the
blank holder 44 are substantially on the same level and
substantially at the same height with each other. Therefore, any
other portion of the blank S after subjected to the first
intermediate pressing step than the concave portion 4 is in contact
with the portion of the end surface of the center die 43
corresponding to the frame portion 3 and the end surface of the
blank holder 44. Meanwhile, the part of the end surface of the
center punch 41 corresponding to the frame portion 3 and the end
surface of the outer punch 42 are substantially on the same level
and substantially at the same height with each other.
[0167] After the blank S with the concave portion 4 is placed on
the center die 43 and the blank holder 44, the upper holder 45 is
lowered. Consequently, as shown in FIG. 8B, the punch end surface
of the center punch 41 and the punch end surface of the outer punch
42 are brought into contact with the blank S. Thereby, the portions
of the blank S corresponding to the concave portion 4 and the frame
portion 3 are pinched between the center punch 41 and the center
die 43, and the other portion of the blank S is pinched between the
outer punch 42 and the blank holder 44.
[0168] Thereafter, the upper holder 45 is moved further down. In
this regard, while the portions of the blank S corresponding to the
concave portion 4 and the frame portion 3 are kept pinched between
the center punch 41 and the center die 43 and while the other
portion of the blank S is kept pinched between the outer punch 42
and the blank holder 44, the outer punch 42 and the blank holder 44
are moved down relative to the center punch 41 and the center die
43. Thereby, the blank S is pressed for forming of the first
vertical wall section 5A and the intermediate flange 7A, and the
intermediate formed product 1A is produced (see FIG. 8C). Thus,
while the concave portion 4 and the frame portion 3 of the blank S
are held, pressing for forming of the first vertical wall section
5A and the intermediate flange 7A is carried out.
[0169] In the second embodiment also, first the concave portion 4
is formed in the blank 5, and thereafter, the frame portion 3, the
first vertical wall section 5A and the intermediate flange 7A,
which are at the outer side of the concave portion 4, are formed.
For the same reason as described in connection with the first
embodiment, the intermediate formed product 1A is unlikely to have
wrinkles, cracks and other defects.
[0170] In FIG. 7B, when the end surface of the center punch 31 and
the end surface of the blank holder 33 make contact with the blank
S, the gap between the end surface of the blank holder 33 and the
end surface of the die 32 is preferably of a size corresponding to
the plate thickness of the blank S plus an additional space of
about 0.1 mm (more specifically, for example, 0.05 to 0.3 mm). The
gap size can be achieved in a structure as follows, for example. A
spacer (not shown) is attached to a part of the outer edge of the
end portion of the die 32. The spacer has a thickness corresponding
to the gap size, and the spacer contacts the blank holder 33.
Therefore, the blank S is pinched loosely and held in the gap
between the die 32 and the blank holder 33. However, when the
additional space increases the risk of causing wrinkles, it is not
necessary to make the additional space, and a pinching force may be
applied to the blank S within a degree not to cause wrinkles.
[0171] Likewise, in FIG. 8B, when the end surface of the center
punch 41 and the end surface of the outer punch 42 make contact
with the blank S, the gap between the end surface of the outer
punch 42 and the end surface of the blank holder 44 is preferably
of a size corresponding to the plate thickness of the blank S plus
an additional space of about 0.1 mm (more specifically, for
example, 0.05 to 0.3 mm). The gap size can be achieved in a
structure as follows, for example. A spacer (not shown) is attached
to a part of the outer edge of the end surface of the blank holder
44. The spacer has a thickness corresponding to the gap size, and
the spacer contacts the outer punch 42. Therefore, the blank S is
pinched loosely and held in the gap between the outer punch 42 and
the blank holder 44.
[0172] The intermediate pressing step may be carried out as cold
pressing or warm pressing. Here, cold pressing means pressing at
room temperature (around 25.degree. C.). Hot pressing means
pressing at a temperature of 100.degree. C. to not more than the
transformation point A.sub.1 of the material of the blank S.
Alternatively, the blank S may be heated to the transformation
point A.sub.1 or higher, and then, the intermediate pressing step
may be carried out as hot pressing. Here, hot pressing means
pressing at a temperature equal to or higher than the
transformation point A.sub.1.
[Heating Step and Final Pressing Step]
[0173] The intermediate formed product 1A produced in the
intermediate pressing step is heated in the heating step. The
heated intermediate formed product 1A is pressed and quenched (that
is, hot stamped) by use of a final pressing machine, and thereby,
the panel-like formed product 1 is produced. The heating step and
the final pressing step will be described in detail below.
[Heating Step]
[0174] In the heating step, the intermediate formed product 1A is
heated by use of a heating device. For example, as shown in FIG. 9,
the intermediate formed product 1A is put into a batch-type heating
furnace 60 and heated therein. In the heating step, the
intermediate formed product 1A is desirably heated at a temperature
equal to or higher than the transformation point A.sub.1 of the
material steel plate of the intermediate formed product 1A, and
more desirably, the intermediate formed product 1A is heated to a
temperature equal to or higher than the transformation point
A.sub.3 of the material steel plate. The heating temperature is
desirably not lower than 700.degree. C., and more desirably not
lower than 900.degree. C. The heating temperature is desirably not
higher than 980.degree. C. The heating may be performed by
electrification instead of using the batch-type heating
furnace.
[0175] When the intermediate formed product 1A is heated at a
temperature equal to or higher than the transformation point
A.sub.1, the microstructure after subjected to hot stamping
(quenching), which will be described later, will include
martensite. Accordingly, the panel-like formed product will have
higher strength. The heating temperature is adjusted appropriately
according to the kind, the degree of difficulty in being formed,
and the like of the material steel. After the heating, the
intermediate formed product 1A is taken out of the heating furnace
60, and is subjected to hot stamping.
[Final Pressing Step]
[0176] In this example, in the final pressing step, the heated
intermediate formed product 1A is hot stamped by use of a final
pressing machine. Thereby, the panel-like formed product 1 to be
typically used as a door inner panel is produced.
[0177] The hot stamping is pressing the heated intermediate formed
product 1A and quenching the heated intermediate formed product 1A
by rapidly cooling it. The hot stamping introduces martensite in
the microstructure of the panel-like formed product 1 made of a
steel plate and thereby allows the panel-like formed product 1 to
have higher strength.
[Final Pressing Machine]
[0178] FIG. 10A is a schematic view of a final pressing machine 50
used in the final pressing step. In reference to FIG. 10A, the
final pressing machine 50 includes a center punch 51 and an outer
punch 52 as upper dies, and includes a center die 53 and a blank
holder 54 as lower dies.
[0179] The punch end surface of the center punch 51 has a shape
corresponding to the top board 2 (the concave portion 4 and the
frame portion 3) of the panel-like formed product 1, and the part
of the side surface thereof adjacent to the punch end surface has a
shape corresponding to the first vertical wall section 5A. The
outer punch 52 is located at the outer side of the center punch 51
and adjacent to the center punch 51. There is a clearance between
the outer punch 52 and the center punch 51. In this example, the
end surface of the outer punch 52A is substantially flat and faces
the end surface 54A of the blank holder 54.
[0180] The center die 53 includes an end surface 53A and a side
surface 53C. The end surface 53A includes a concave portion 531, an
edge portion 532, a vertical wall portion 533, and a stair portion
534. The concave portion 531 has a shape corresponding to the shape
of the concave portion 4 of the panel-like formed product 1. The
edge portion 532 is positioned at the outer side of the concave
portion 531 and adjacent to the concave portion 531. The edge
portion 532 connects to the concave portion 531. The edge portion
532 has a shape corresponding to the frame portion 3 of the
panel-like formed product 1. The vertical wall portion 533 extends
downward from the edge portion 532. The vertical wall portion 533
has a shape corresponding to the first vertical wall section 5A of
the panel-like formed product 1. The stair portion 534 is
positioned at the outer side of the vertical wall portion 533 and
connects to the lower end of the vertical wall portion 533. The
stair portion 534 has a shape corresponding to the stair 6 of the
panel-like formed product 1. Accordingly, the height difference
between the stair portion 534 and the edge portion 532 corresponds
to the height H1 of the stair of the panel-like formed product
1.
[0181] The side surface 53C extends from the outer edge of the
stair portion 534 down toward the lower end of the final pressing
machine 50. The side surface 53C has a shape corresponding to the
shape of the second vertical wall section 5B of the panel-like
formed product 1. The end surface 53A of the center die 53 faces
the end surface of the center punch 51.
[0182] The blank holder 54 is located at the outer side of the
center die 53 and adjacent to the center die 53. There is a
clearance between the blank holder 54 and the center die 53. The
end surface 54A of the blank holder 54 is flat. The end surface 54A
of the blank holder 54 faces the end surface 52A of the outer punch
52.
[0183] The center punch 51 and the outer punch 52 are supported by
an upper holder 55. The center punch 51 is fastened to the upper
holder 55 in such a way as to be movable up and down relative to
the outer punch 52. For example, the center punch 51 is supported
by the upper holder 55 via a pressing member (not shown). However,
for example, the center punch 51 and the outer punch 52 may be
fastened to the upper holder 55 in such a way as to be movable up
and down independently of each other. The upper holder 55 is
fastened to a lifting and lowering device (slide) (not shown) and
is movable up and down.
[0184] The center die 53 and the blank holder 54 are supported by a
lower holder 56. The blank holder 54 is supported by the lower
holder 56 in such a way as to be movable up and down relative to
the center die 53. For example, the blank holder 54 is supported by
the lower holder 56 via a pressing member (not shown). However, for
example, the center die 53 and the blank holder 54 may be fastened
to the lower holder 56 in such a way as to be movable up and down
independently of each other.
[0185] As shown in FIG. 10A, the initial height of the end surface
54A of the blank holder 54 is lower than the height of the stair
portion 534 of the center die 53. For example, at an early stage
(before pressing) of the final pressing step, as shown in FIG. 10A,
there is an initial height difference h0 between the end surface
54A and the stair portion 534. The initial height difference h0 is,
for example, 1.0 to 5.0 mm.
[0186] The final pressing step to be carried out by use of the
final pressing machine 50 includes an early step and a late step as
follows.
[0187] Early step: The intermediate formed product 1A is placed on
the center die 53, and the intermediate formed product 1A is
pinched between the center punch 51 and the center die 53 and
further pinched between the outer punch 52 and the blank holder
54.
[0188] Late step: The outer punch 53 and the blank holder 54 with
the intermediate formed product 1A pinched in between are moved
relative to the center punch 51 and the center die 53 with the
intermediate formed product 1A pinched in between, and thereby, the
panel-like formed product 1 is produced.
[0189] By pinching the center portion of the intermediate formed
product 1A between the center die 53 and the center punch 51 at the
early step and by carrying out pressing at the late step by moving
the outer punch 52 and the blank holder 54 with the intermediate
formed product 1A pinched in between relative to the center die 53
and the center punch 51, it is possible to suppress generation of
wrinkles in the panel-like formed product 1.
[0190] When hot stamping is carried out in the late step, the early
step includes a first step and a second step as follows.
[0191] First step: The intermediate formed product 1A is
positioned, the intermediate formed product 1A is pinched between
the center punch 51 and the center die 53, and the outer punch 52
is brought into contact with the intermediate product 1A.
[0192] Second step: After the outer punch 52 is brought into
contact with the intermediate formed product 1A, while the
intermediate product 1A is kept pinched between the center punch 51
and the center die 53, the blank holder 54 is brought into contact
with the intermediate formed product 1A, and thereby, the
intermediate formed product 1A is pinched between the outer punch
52 and the blank holder 54.
[0193] By carrying out the first step and the second step, the
blank holder 54 is prevented from contacting the intermediate
formed product 1A until the outer punch 52 is brought into contact
with the intermediate formed product 1A. This prevents the portion
of the intermediate formed product 1A to be pressed at the late
step from dropping in temperature before pressing starts in the
late step. Accordingly, in the pressing in the late step, the
intermediate formed product 1A can maintain sufficient
hardenability while maintaining workability. The early step and the
late step will be described below.
[Early Step]
[0194] In a case in which hot stamping is carried out in the final
pressing step as in this example, the early step includes the first
step and the second step.
[First Step]
[0195] In the first step, first, the intermediate formed product 1A
which was heated in the heating step is placed on the center die 53
and the blank holder 54 of the final pressing machine 50 as shown
in FIG. 10A.
[0196] When the intermediate formed product 1A is placed on the
center die 53, the concave portion 531 of the end surface 53A of
the center die 53 makes contact with the concave portion 4 of the
intermediate formed product 1A, the edge portion 532 of the end
surface 53A of the center die 53 makes contact with the frame
portion 3 of the intermediate formed product 1A, and the vertical
wall portion 533 of the end surface 53A of the center die 53 makes
contact with the first vertical wall section 5A of the intermediate
formed product 1A. The stair portion 534 of the end surface 53A of
the center die 53 makes contact with the intermediate flange 7A of
the intermediate formed product 1A.
[0197] Meanwhile, the end surface 54A of the blank holder 54 is
located at a height that is lower than the stair portion 534 by the
initial height difference h0. Therefore, when the intermediate
formed product 1A is placed on the center die 53, the intermediate
formed product 1A does not make contact with the blank holder
54.
[0198] After the intermediate formed product 1A is placed on the
center die 53, the center punch 51 and the outer punch 52 are moved
down. In this regard, while the portion of the end surface of the
center punch 51 corresponding to the stair 6 of the panel-like
formed product 1 is kept substantially at the same height as the
end surface 52A of the outer punch 52, the center punch 51 and the
outer punch 52 are moved down.
[0199] As the center punch 51 and the outer punch 53 are moved
down, and as shown in FIG. 10C, the intermediate formed product 1A
is pinched between the center punch 51 and the center die 53.
Almost at the same time when the center punch 51 is brought into
contact with the intermediate formed product 1A, the end surface
52A of the outer punch 52 is brought into contact with the
intermediate formed product 1A (the intermediate flange 7A). At the
time, as shown in FIG. 10C, the end surface 54A of the blank holder
54 is not in contact with the intermediate formed product 1A. Thus,
in the first step, the intermediate formed product 1A is pinched
between the center punch 51 and the center die 53, and the outer
punch 52 is brought into contact with the intermediate formed
product 1A with the blank holder 54 kept out of contact with the
intermediate formed product 1A.
[0200] Since the intermediate flange 7A is out of contact with the
end surface 54A of the blank holder 54 at the time, the
intermediate flange 7A does not drop in temperature easily before
pressing starts. Thus, it is possible to suppress a temperature
drop of the intermediate formed product 1A before pressing and
thereby to maintain good workability.
[0201] The initial height difference h0 is preferably 1.0 to 5.0
mm. The initial height difference h0 of not less than 1.0 mm
secures a sufficient space between the blank holder 54 and the
intermediate formed product 1A when the punch 52 is brought into
contact with the intermediate product 1A. In this case, the end
surface 54A of the blank holder 54 is not brought into contact with
the intermediate formed product 1A until the end surface 52A of the
outer punch 52 is brought into contact with the intermediate formed
product 1A. Accordingly, a temperature drop of the intermediate
formed product 1A can be suppressed sufficiently before pressing is
performed by pinching the intermediate formed product 1A between
the outer punch 52 and the blank holder 54. Consequently, lowering
of the workability of the intermediate formed product 1A can be
suppressed, and the intermediate formed product 1A can be quenched
enough.
[0202] The initial height difference h0 of not more than 5.0 mm
avoids making too large a space between the blank holder 54 and the
intermediate formed product 1A and thereby secures an appropriate
sized space therebetween. This shortens the time period from the
time when the outer punch 52 is brought into contact with the
intermediate formed product 1A till the time when the intermediate
formed product 1A is brought into contact with the blank holder 54,
which leads to further suppression of generation of wrinkles and
the like during pressing.
[0203] The initial height difference h0 is not limited to 1.0 to
5.0 min. There is no particular limit to the initial height
difference h0 as long as it prevents the end surface 54A of the
blank holder 54 from making contact with the intermediate formed
product 1A when the end surface 52A of the outer punch 52 is
brought into contact with the intermediate formed product 1A as
shown in FIG. 10C.
[Second Step]
[0204] The intermediate formed product 1A is pinched between the
center punch 51 and the center die 53, and the outer punch 52 is
brought into contact with the intermediate formed product 1A.
Thereafter, in the second step, while the intermediate formed
product 1A is kept pinched between the center punch 51 and the
center die 53, the blank holder 54 is further brought into contact
with the intermediate formed product 1A, and thereby, the
intermediate formed product 1A is pinched between the outer punch
52 and the blank holder 54 (see FIG. 10D).
[0205] In this example, after the outer punch 52 is brought into
contact with the intermediate formed product 1A, the outer punch 52
is moved down relative to the center punch 51 while the
intermediate formed product 1A is kept pinched between the center
punch 51 and the center die 53. Thereby, the intermediate flange 7A
of the intermediate formed product 1A is slightly deformed, and the
intermediate flange 7A makes contact with the end surface 54A of
the blank holder 54 while being in contact with the end surface 52A
of the outer punch 52. Then, the intermediate formed product 1A
(the intermediate flange 7A) is pinched between the outer punch 52
and the blank holder 54.
[0206] As described above, the blank holder 54 is not brought into
contact with the intermediate formed product 1A until the outer
punch 52 is brought into contact with the intermediate product 1A.
In other words, after the outer punch 52 is brought into contact
with the intermediate formed product 1A (for example, when the
outer punch 52 is moved further down by 1.0 to 5.0 mm after being
brought into contact with the flange 7A of the intermediate formed
product 1A), the blank holder 54 makes contact with the
intermediate flange 7A of the intermediate formed product 1A. Thus,
while the intermediate formed product 1A is kept pinched between
the center punch 51 and the center die 53, the intermediate formed
product 1A is pinched between the outer punch 52 and the blank
holder 54.
[Late Step]
[0207] After the intermediate flange 7A of the intermediate formed
product 1A is pinched between the outer punch 52 and the blank
holder 54 at the early step (the second step), the outer punch 52
and the blank holder 54 with the intermediate formed product 1A
pinched in between are moved down relative to the center punch 51
and the center die 53 with the intermediate formed product 1A
pinched in between. Thereby, as shown in FIG. 10E, the second
vertical wall section 5B and the flange 7 are formed, and the
panel-like formed product 1 is produced. In this example, the outer
punch 52 and the blank holder 54 with the intermediate formed
product 1A pinched in between are moved further down, and pressing
(hot stamping) is carried out. When the outer punch 52 is moved
down by a distance corresponding to the height of the second
vertical wall section 5B of the panel-like formed product 1 after
making contact with the intermediate flange 7A, the downward motion
of the outer punch 52 is stopped. In this way, the panel-like
formed product 1 is produced.
[0208] Water or any other cooling medium is circulated in the
center punch 51, the outer punch 52, the center die 53 and the
blank holder 54. Therefore, the intermediate formed product 1A
undergoing pressing is rapidly cooled. Thus, in the final pressing
step, the intermediate formed product 1A is pressed and in the
meantime, rapidly cooled (quenched).
[0209] As described above, in the final pressing step, the
intermediate formed product 1A is pressed and in the meantime,
quenched. This allows the panel-formed product 1 to have a
microstructure including martensite. Accordingly, the thus
manufactured panel-like formed product 1 has high strength.
[0210] In the embodiment, in the early step, first, the outer punch
52 is brought into contact with the intermediate formed product 1A
(first step), and thereafter, the blank holder 54 is brought into
contact with the intermediate formed product 1A (second step). If
the end surface 54A of the blank holder 54 is at the same height as
the stair portion 534 of the center die 53, when the intermediate
formed product 1A is placed on the center die 53, the intermediate
flange 7A to be pressed will make contact with the blank holder 54.
In this case, the temperature of the intermediate flange 7A will
become lower before the outer punch 52 is brought into contact with
the flange 7A. This makes the pressing difficult. Also, this makes
it difficult to perform the quenching sufficiently.
[0211] In the embodiment, on the other hand, when the intermediate
formed product 1A is placed on the center die 53, the blank holder
54 does not make contact with the intermediate formed product 1A.
After the intermediate formed product 1A is pinched between the
center punch 51 and the center die 53, and after the outer punch 53
is brought into contact with the intermediate flange 7A of the
intermediate formed product 1A, the blank holder 54 is brought into
contact with the intermediate flange 7A. This prevents the
intermediate flange 7A of the intermediate formed product 1A from
dropping in temperature before being pressed by the outer punch 52
and the blank holder 54. This reduces a risk of a decrease in
workability of the intermediate formed product 1A caused by a
temperature drop of the intermediate flange 7A, which allows the
quenching to be performed sufficiently.
[0212] In a state in which the intermediate flange 7A of the
intermediate formed product 1A is pinched between the outer punch
52 and the blank holder 54, the gap between the end surface 52A of
the outer punch 52 and the end surface 54A of the blank holder 54
is preferably of a size corresponding to the plate thickness of the
intermediate formed product 1A plus about 0.1 mm (for example, the
plate thickness of the intermediate formed product 1A plus 0.05 to
0.3 mm).
[0213] For example, a spacer (not shown) is attached to a part of
the outer edge of the end surface 54A of the blank holder 54. The
spacer has a thickness corresponding to the plate thickness of the
intermediate formed product 1A plus about 0.1 mm (for example, 0.05
to 0.3 mm). Accordingly, when the intermediate formed product 1A is
pinched between the outer punch 52 and the blank holder 54, the
outer punch 52 is brought into contact with the spacer attached to
the blank holder 54. Then, the gap between the outer punch 52 and
the blank holder 54 is of the size above. In this case, the
intermediate formed product 1A is pinched between the outer punch
52 and the blank holder 54 loosely. Therefore, the intermediate
formed product 1A is not held too tight, and the material is easily
drawn as the intermediate formed product 1A is being deformed.
Thus, the pressing is performed smoothly.
[0214] Further, when the stair 6, the second vertical wall section
5B and the flange 7 are to be formed by hot stamping, the top board
2 of the intermediate formed product 1A and the portion of the
intermediate flange 7A to be formed into the stair 6 are pinched
and held between the center punch 51 and the center die 53. This
suppresses generation of wrinkles and other defects in the
panel-like formed product 1. This point will be described
below.
[Suppression of Generation of Cracks and Wrinkles]
[0215] FIG. 11 is a sectional view showing pressing by use of a
conventional final pressing machine. FIG. 11 enlarges a stair-like
portion of a punch of the conventional final pressing machine. In
the conventional final pressing machine 200, a punch 220 has a
stair surface 220B and a reference surface 220C which are
integrally formed. Therefore, during pressing, before the end
surface 220A and the stair surface 220B of the punch 220 reach the
end surface 210A and the stair surface 210B of the die 210, the
reference surface 220C of the punch 220 reaches the end surface
230C of the blank holder 230. At the time, a portion S1 of the
blank S to be pressed by the stair surface 220B of the punch 220 is
not held. In other words, the portion S1 of the blank S is neither
in contact with the die 210 nor in contact with the punch 220.
[0216] As shown in FIG. 11, while the die 210 and the punch 220 are
processing the blank S, the blank S is pulled toward the end
surface 220A of the punch 200. Therefore, the material of the blank
S is likely to flow from the portion to be pinched between the
blank holder 230 and the punch 220 to the portion S1. When the
portion S1 is pressed with the material flowing thereinto, wrinkles
are likely to be generated in the portion S1. This is because of
excess material that flowed into and present in the portion S1.
During the pressing, the portion S1 is not held and accordingly is
under tension. When the portion S1 under tension is pressed, cracks
are likely to be generated in the portion S1. Especially when the
plate thickness of the blank S is thin, cracks are more likely to
be generated.
[0217] In view of this, according to the embodiment, the pressing
step is divided into an intermediate pressing step and a final
pressing step. In the intermediate pressing step, an intermediate
formed product 1A with the same shape as the panel-like formed
product 1 in the portion up to the stair 6 is produced. Then, in
the final pressing step, while the concave portion 4, the frame
portion 3, the first vertical wall section 5A and the portion
corresponding to the stair 6 of the intermediate formed product 1A
are pinched and held, the intermediate flange 7A of the
intermediate formed product 1A is pinched and pressed by the outer
punch 52 and the blank holder 54. In this regard, in the portion of
the intermediate formed product 1A to be pressed, a free portion
which is not held (a portion like the portion S1 shown in FIG. 11)
is very small. Therefore, generation of cracks and wrinkles is
suppressed.
[0218] The effect to suppress generation of wrinkles and cracks
brought by performing pressing in two stages, namely, the
intermediate pressing step and the final pressing step is obtained
both in a case in which hot stamping is performed in the final
pressing step and in a case in which cold pressing is performed
with the heating step not performed in the final pressing step as
will be described below.
[0219] In the case in which hot stamping is performed in the final
pressing step, the early step need not be divided into the first
step and the second step. In other words, the blank holder 54 may
be brought into contact with the intermediate formed product 1A
before the outer punch 52 is brought into contact with the
intermediate formed product 1A. Even in this case, since pressing
is performed in two stages, namely, in the intermediate pressing
step and the final pressing step, generation of wrinkles and the
like can be suppressed. However, when hot stamping is performed in
the final pressing step, it is preferred that the early step of the
final pressing step is divided into the first step and the second
step. In this case, the portion of the intermediate formed product
1A to be pressed in the final pressing step can be prevented from
dropping in temperature, and this allows the intermediate formed
product 1A to maintain sufficient workability and
hardenability.
[0220] Regarding suppression of generation of cracks and wrinkles
in the panel-like formed product 1, the same applies to the
intermediate pressing step to form the blank S into the
intermediate formed product 1A. In the intermediate pressing step,
at the second intermediate pressing step to form the frame portion
3 and the first vertical wall section 5A in the blank S, the
concave portion 4, which has been formed at the first intermediate
pressing step, and the portion of the blank S to be formed into the
frame portion 3 are held (see FIGS. 6B, 6C, 8B and 8C). Thus, at
the second intermediate pressing step, a free portion like the
portion S1 of the blank S shown in FIG. 11 is small. Accordingly,
wrinkles and the like are unlikely to be generated in the
intermediate formed product 1A.
[0221] As described above, in the intermediate pressing step, the
intermediate formed product 1A may be formed by cold pressing. Even
in the cold pressing, however, if a free portion like the portion
S1 of the blank S shown in FIG. 11 is present at the time of
pressing, wrinkles and the like are likely to be generated. In view
of this, in the intermediate pressing step according to the
embodiment, at the second intermediate pressing step, the frame
portion 3 and the vertical wall 5A are formed while the concave
portion 4 and the portion to be formed into the frame portion 3 are
held. Thus, whether the intermediate pressing step is cold
pressing, warm pressing or hot pressing, wrinkles and the like are
unlikely to be generated in the intermediate formed product 1A.
[0222] In the case in which hot stamping is performed in the final
pressing step, the blank S is cooled by contact with the punches,
dies and blank holder. In the case in which hot stamping is
performed by use of the conventional final pressing machine shown
in FIG. 11, however, the portion S1 of the blank S is not cooled
for the reason as described above. The portion S1 of the blank S is
cooled when the punch 220 is moved further down from the position
shown in FIG. 11. Thus, when a panel-like formed product with a
stair in vertical walls is formed by use of a single-body punch
220, the portion S1 of the blank S is cooled later than the other
portions as described above.
[0223] When a part of the blank S is cooled later, it causes
variation of the blank S in strength and ductility. Therefore, in
the case in which hot stamping is performed in the final pressing
step, wrinkles are more likely to be generated in the panel-like
formed product. As shown in FIG. 1, when the panel-like formed
product 1 has a stair 6 in adjacent vertical walls 5 so as to be
usable typically as a door inner panel, cracks, wrinkles and the
like are especially likely to be generated.
[0224] According to the embodiment, on the other hand, while the
portions of the intermediate formed product 1A corresponding to the
concave portion 4, the frame portion 3, the first vertical wall
section 5A and the stair 6 are pinched between the center punch 51
and the center die 53, pressing is carried out by pinching the
intermediate flange 7A of the intermediate formed product 1A
between the outer punch 52 and the blank holder 54. AT the time, in
the portion of the intermediate formed product 1A to be pressed, a
free portion which is not held is small. Therefore, even in the
case in which hot stamping is performed in the final pressing step,
generation of wrinkles and the like can be suppressed.
[0225] The above-described embodiments are cases in which the
material of the panel-like formed product 1 is a steel plate.
However, the present invention is applicable to a case of producing
the panel-like formed product 1 from any other metal plate as well
as a steel plate. The metal plate is, for example, an aluminum
plate, an aluminum alloy plate, a multilayer steel plate, a
titanium plate, a magnesium plate, or the like.
[Performing Cold Pressing Instead of Hot Stamping in Final Pressing
Step]
[0226] In the embodiments above, in the final pressing step, a
heating treatment is carried out, and hot stamping is performed.
However, in the final pressing step of the production process, the
intermediate formed product 1A may be cold pressed with the heating
step omitted and thereby formed into the panel-like formed product
1. When a steel plate is used as the blank, the panel-like formed
product 1 produced by cold pressing in the final pressing step
preferably has a tensile strength of not less than 340 MPa. A case
in which cold pressing is performed in the final pressing step will
be described below.
[0227] In a case in which cold pressing is performed in the final
pressing step, a final pressing machine having the same structure
as the final pressing machine 50 shown in FIG. 10A is used.
However, it is not necessary to circulate a cooling medium in the
center punch 51, the outer punch 52, the center die 53 and the
blank holder 54. Also, in the case of cold pressing, the end
surface 54A of the blank holder 54 may be positioned at the same
height as the stair portion 534 of the center die 53.
[0228] The method for manufacturing the panel-like formed product 1
by performing cold pressing by use of the final pressing machine
having the structure shown in FIG. 10A includes a preparing step,
an intermediate pressing step, and a final pressing step. Thus, in
the case of cold pressing, the heating step is omitted as compared
with the case in which hot stamping is performed.
[0229] The final pressing step includes an early step and a late
step as follows.
[0230] Early step: The intermediate formed product 1A (at room
temperature) is placed on the center die 53, and the intermediate
formed product 1A is pinched between the center punch 52 and the
center die 53 and further pinched between the outer punch 52 and
the blank holder 54.
[0231] Late Step: The outer punch 52 and the blank holder 54 with
the intermediate formed product 1A pinched in between is moved
relative to the center punch 51 and the center die 53 with the
intermediate formed product 1A pinched in between, and the
panel-like formed product 1A is produced.
[0232] The respective steps will be described below.
[Early Step]
[0233] In the case in which the intermediate formed product 1A is
formed into the panel-like formed product 1 by cold pressing, at
the early step of the final pressing step, the intermediate formed
product 1A is placed on the center die 53 and the blank holder 54.
After the placement, the center punch 51 and the outer punch 52 are
moved down. In this regard, while the portion of the end surface of
the center punch 51 corresponding to the stair 6 of the panel-like
formed product 1 is kept substantially at the same height as the
end surface 52A of the outer punch 52, the center punch 51 and the
outer punch 52 are moved down. Thereby, the intermediate formed
product 1A is pinched between the center punch 51 and the center
die 53, and the intermediate flange 7A of the intermediate formed
product 1A is pinched between the outer punch 52 and the blank
holder 54.
[Late Step]
[0234] After the early step, while the intermediate formed product
1A is kept pinched between the center punch 51 and the center die
53 and while the intermediate flange 7A of the intermediate formed
product 1A is pinched between the outer punch 52 and the blank
holder 54, the outer punch 52 and the blank holder 54 are moved
further down. Thereby, the intermediate flange 7A is pressed into
the second vertical wall section 5B and the flange 7B, and
consequently, the panel-like formed product 1 is produced.
[0235] In the case in which cold pressing is performed instead of
hot stamping, the early step need not be divided into the first
step and the second step. The first step and the second step are to
prevent the portion of the intermediate formed product 1A to be
pressed (the outer portion of the intermediate formed product 1A)
from dropping in temperature before undergoing hot stamping. In the
case in which the intermediate formed product 1A is to be cold
pressed without heated, the intermediate formed product 1A is not
at high temperature, and the early step need not be divided into
the first step and the second step.
[0236] As mentioned above, even in the case in which not hot
stamping but cold pressing is performed in the final pressing step,
since the intermediate pressing step and the final pressing step
are carried out, generation of wrinkles and cracks in the
panel-like formed product can be suppressed as in the case in which
hot stamping is performed in the final pressing step.
[0237] In producing the panel-like formed product 1 as shown in
FIG. 4, which includes a depression 11 and/or a projection in the
concave portion 4, it is possible to form the depression 11 and/or
the projection in the intermediate pressing step. Alternatively, an
intermediate depression and/or an intermediate projection may be
formed in the concave portion 4 in the intermediate pressing step,
and thereafter, the intermediate depression and/or the intermediate
projection mat be formed into the depression 11 and/or the
projection in the final pressing step.
[0238] In any of the pressing machines (including the intermediate
pressing machines 20, 30 and 40, and the final pressing machine
50), the arrangement of the punches, dies and blank holder is not
limited to those shown in the drawings. In each of the pressing
machines, the upper dies and the lower dies, which are composed of
punches, dies, a blank holder, and the like, may be arranged upside
down.
EXAMPLES
[0239] In order to confirm the effects of the manufacturing methods
according to the embodiments, analysis was conducted by the FEM
(finite element method). As an inventive example, it was assumed
that the panel-like formed product 1 (door inner panel) shown in
FIG. 1 was produced by the manufacturing method according to the
first embodiment by use of the intermediate pressing machine 20
shown in FIG. 6 and the final pressing machine 50 shown in FIG.
10A. As a comparative example, meanwhile, it was assumed that a
panel-like formed product (door inner panel) similar to the
inventive example was produced by use of the conventional hot
stamping machine shown in FIG. 11. The inventive example and the
comparative example were analyzed in the following way, and the
panel-like formed products were evaluated with respect to
generation of wrinkles based on the analysis results.
[Analysis Condition]
[0240] As the material (as the intermediate formed product 1A in
the inventive example and as the blank in the comparative example),
a steel plate containing, at mass %, C: 0.21%, Si: 0.25%, Mn:
1.20%, B: 0.0020% and containing iron and impurities as the balance
was used. The plate thickness of the blank was 1.2 mm. The blank
after quenching had the following material characteristics; a
Vickers hardness of 448; a yield strength of 448 MPa; a tensile
strength of 1501 MPa; and a breaking elongation of 6.4%. The
material was heated to 750.degree. C. In the hot stamping, the die
was moved at a speed equivalent to 40 m/s. In the hot stamping, the
coefficient of friction between the die and the material was 0.4. A
temperature-forming interaction analysis was performed by use of
general-purpose FEM analysis software (LS-DYNA (tradename)
manufactured by LIVERMORE SOFTWARE TECHNOLOGY).
[0241] Each of the panel-like formed products of the inventive
example and the comparative example, which are to be used as door
inner panels, had the following dimensions.
[0242] Entire length (including a flange): 950 mm
[0243] Entire width (including a flange): 670 mm
[0244] Entire length of the top board: 830 mm
[0245] Entire width of the top board: 600 mm
[0246] Height of the first vertical wall section: 40 mm
[0247] Height of the second vertical wall section: 40 mm
[0248] Minimum width of the stair: 40 mm
[0249] In the hot stamping of the inventive example, the initial
height of the end surface 54A of the blank holder 54 was 3.0 mm
lower than the initial height of the stair portion 534 of the
center die 53. Therefore, in the inventive example, when the second
die was moved down by 3.0 mm after the center punch 51 and the
outer punch 52 had made contact with the intermediate formed
product, the blank holder 54 made contact with the intermediate
formed product 1A.
[Evaluation Method]
[0250] About each of the panel-like formed product of the inventive
example and the comparative example, the curvature of a concavity
or convexity on the surface of the stair 6 was examined. The
curvature was calculated as follows.
[0251] (Curvature[1/m])=(1/(radius of curvature))
[0252] Sections of each of the panel-like formed products along
lines perpendicular to the surface of the stair 6 were obtained,
and in each of the sections, the curvature radii of the respective
concavities and convexities on the surface of the stair 6 were
calculated. The minimum value among the results was adopted as the
radius of curvature in the above formula. Then, when the curvature
was equal to or more than 0.01, the panel-like formed product was
evaluated as having wrinkles.
[Analysis Results]
[0253] In the inventive example, there were no sections in which
the curvature was 0.01 or more. Accordingly, the inventive example
was evaluated as having no wrinkles. In the comparative example, on
the other hand, there were many sections in which the curvature was
0.01 or more. Accordingly, the comparative example was evaluated as
having wrinkles.
[0254] Some embodiments of the present invention have been
described above. However, the above-described embodiments are
merely examples to show how to carry out the present invention.
Therefore, the present invention should not be limited to the
embodiments above, and it is possible to modify the embodiments
appropriately without departing from the spirit and scope of the
present invention.
LIST OF REFERENCE SYMBOLS
[0255] 1, 10: panel-like formed product
[0256] 1A: intermediate formed product
[0257] 2: top board
[0258] 3: frame portion
[0259] 4: concave portion
[0260] 5: vertical wall
[0261] 6: stair
[0262] 7: flange
[0263] 8: window member
[0264] 50: final pressing machine
* * * * *